Illumination systems utilizing multiple wavelength light recycling

ABSTRACT

An illumination system has a light source and a wavelength conversion layer within a light-recycling envelope. The light source is a light-emitting diode or a semiconductor laser. The light source will emit light of a first wavelength range that is transmitted through the wavelength conversion layer in order to convert a portion of the light of a first wavelength range into light of a second wavelength range. Light of both the first and second wavelength ranges will exit the light-recycling envelope through an aperture. The recycling of the light by the light-recycling envelope will enhance the output radiance and luminance of the light exiting the illumination system.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 10/445,136 filed May 23, 2003, now U.S. Pat. No. 6,869,206entitled “ILLUMINATION SYSTEMS UTILIZING HIGHLY REFLECTIVE LIGHTEMITTING DIODES AND LIGHT RECYCLING TO ENHANCE BRIGHTNESS,” which isherein incorporated by reference. This application is also related toU.S. patent application Ser. No. 10/814,043 entitled “ILLUMINATIONSYSTEMS UTILIZING LIGHT EMITTING DIODES AND LIGHT RECYCLING TO ENHANCEOUTPUT RADIANCE” and to U.S. patent application Ser. No. 10/815,005entitled “PROJECTION DISPLAY SYSTEMS UTILIZING LIGHT EMITTING DIODES ANDLIGHT RECYCLING,” both of which are filed concurrently with thisapplication and which are herein incorporated by reference.

TECHNICAL FIELD

This invention relates to illumination systems incorporating lightsources and wavelength conversion layers. The light sources are eitherlight-emitting diodes (LEDs) or semiconductor lasers. Light-emittingdiodes include inorganic light-emitting diodes and organiclight-emitting diodes (OLEDs). Semiconductor lasers includeedge-emitting diode lasers and vertical cavity surface emitting-lasers(VCSELs).

BACKGROUND OF THE INVENTION

Illumination systems are used as either stand-alone light sources or asinternal light sources for more complex optical systems. Examples ofoptical systems that utilize or incorporate illumination systems includeprojection displays, flat-panel displays, avionics displays, automotivelighting, residential lighting, commercial lighting and industriallighting applications.

Many applications require illumination systems with high brightness anda small effective emitting area. An example of a conventional lightsource with high brightness and a small effective emitting area is anarc lamp source, such as a xenon arc lamp or a mercury arc lamp. Arclamp sources may have emitting areas as small as a few squaremillimeters. An example of a complex optical system that can utilize anillumination system with high brightness and a small effective sourcearea is a projection television display. Current projection televisiondisplays typically project the combined images of three small red, greenand blue cathode-ray-tube (CRT) devices onto a viewing screen usingprojection lenses. More recent designs sometimes use a small-area arclamp source to project images from a liquid crystal display (LCD), aliquid-crystal-on-silicon (LCOS) device or a digital light processor(DLP) device onto a viewing screen. Light sources such as LEDs arecurrently not used for projection television displays because LEDsources do not have sufficient output brightness.

The technical term brightness can be defined either in radiometric unitsor photometric units. In the radiometric system of units, the unit oflight flux or radiant flux is expressed in watts and the unit forbrightness is called radiance, which is defined as watts per squaremeter per steradian (where steradian is the unit of solid angle). Thehuman eye, however, is more sensitive to some wavelengths of light (forexample, green light) than it is to other wavelengths (for example, blueor red light). The photometric system is designed to take the human eyeresponse into account and therefore brightness in the photometric systemis brightness as observed by the human eye. In the photometric system,the unit of light flux as perceived by the human eye is called luminousflux and is expressed in units of lumens. The unit for brightness iscalled luminance, which is defined as lumens per square meter persteradian. The human eye is only sensitive to light in the wavelengthrange from approximately 400 nanometers to approximately 700 nanometers.Light having wavelengths less than about 400 nanometers or greater thanabout 700 nanometers has zero luminance, irrespective of the radiancevalues. In this application, illumination systems will be consideredthat incorporate a light source that emits light of a first wavelengthrange and a wavelength conversion layer that converts a portion of thelight of the first wavelength range into light of a second wavelengthrange, different from the first wavelength range. When two wavelengthranges are present, sometimes it is appropriate to consider brightnessin terms of radiance and sometimes it is appropriate to considerbrightness in terms of luminance. In this application, either radianceor luminance or both will be used depending on the circumstances.

In a conventional optical system that transports light from an inputsource at one location to an output image at a second location, onecannot produce an optical output image whose radiance is higher than theradiance of the light source. A conventional optical system 10 of theprior art is illustrated in cross-section in FIG. 1A. In FIG. 1A, lightrays 18 from an input light source 12 are focused by a convex lens 14 toan output image 16. The conventional optical system 10 in FIG. 1A canalso be illustrated in a different manner as optical system 20 shown incross-section in FIG. 1B. For simplicity, the input source 22, the lens24 and the output image 26 are all assumed to be round. In FIG. 1B, theinput source 22 has area, Area_(in). The light rays from input source 22fill a truncated cone having edges 21 and 23. The cone, which is shownin cross-section in FIG. 1B, extends over solid angle 27. The magnitudeof solid angle 27 is Ω_(in). Lens 24 focuses the light rays to image 26having area, Area_(out). The light rays forming the image 26 fill atruncated cone having edges 25 and 29. The cone, which is shown incross-section, extends over solid angle 28. The magnitude of solid angle28 is Ω_(out).

If the optical system 20 has no losses, the light input flux at theinput source 22,Φ_(in)=(Radiance_(in))(Area_(in))(Ω_(in)),  [Equation 1]equals the light output flux at the output image 26,Φ_(out)=(Radiance_(out))(Area_(out))(Ω_(out)).  [Equation 2]In these equations, “Radiance_(in)” is the radiance at the input source22, “Radiance_(out)” is the radiance at the output image 26, “Area_(in)”is the area of the input source 22 and “Area_(out)” is the area of theoutput image 26. The quantities Ω_(in) and Ω_(out) are, respectively,the projected solid angles subtended by the input source and outputimage light cones. In such a lossless system, it can be shown thatRadiance_(in)=Radiance_(out)  [Equation 3]and(Area_(in))(Ω_(in))=(Area_(out))(Ω_(out)).  [Equation 4]If the index of refraction of the optical transmission medium isdifferent at the input source and output image positions, the equalityin Equation 4 is modified to become(n _(in) ²(Area_(in))(Ω_(in))=(n _(out)²(Area_(out))(Ω_(out)),  [Equation 5]where n_(in) is the index of refraction at the input position andn_(out) is the index of refraction at the output position. The quantity(n²)(Area)(Ω) is variously called the “etendue” or “optical extent” or“throughput” of the optical system. In a conventional lossless opticalsystem, the quantity (n²)(Area)(Ω) is conserved.

In U.S. Pat. No. 6,144,536, herein incorporated by reference, Zimmermanet al demonstrated that for the special case of a source that has areflecting emitting surface, an optical system can be designed thatrecycles a portion of the light emitted by the source back to the sourceand transmits the remainder of the light to an output position. Undercertain conditions utilizing such light recycling, the effectivebrightness of the source as well as the output brightness of the opticalsystem can be higher than the intrinsic brightness of the source in theabsence of recycling, a result that is not predicted by the standardetendue equations. In U.S. Pat. No. 6,144,536, the brightness term“luminance” is used for brightness instead of “radiance” but the conceptis equivalent for both optical terms as long as the optical wavelengthis between 400 and 700 nanometers and as long as wavelength conversionis not taking place between the input source and the output image of theoptical system.

An example of a light source with a reflecting emitting surface is aconventional fluorescent lamp. A cross-section of a conventionalfluorescent lamp 30 is shown in FIG. 2A. The fluorescent lamp 30 has aglass envelope 32 enclosing a hollow interior 36. The hollow interior 36is filled with a gas that can emit ultraviolet light when a high voltageis applied. The ultraviolet light excites a phosphor coating 34 on theinside surface of the glass envelope, causing the phosphor to emitvisible light through the phosphor coating 34. The phosphor coating 34is a partially reflecting surface in addition to being a light emitter.Therefore, it is possible to design an optical system that recycles aportion of the visible light generated by the phosphor coating 34 backto the coating 34 and thereby cause an increase in the effectivebrightness of the conventional fluorescent lamp. The disclosures onlight recycling in U.S. Pat. No. 6,144,536 relate to linear lightsources that have long emitting apertures with aperture areas greaterthan 100 square millimeters (mm²). Such configurations are not suitablefor many applications such as illumination systems for large projectiondisplays.

Recently, highly reflective green, blue and ultraviolet LEDs and diodelasers based on gallium nitride (GaN), indium gallium nitride (InGaN)and aluminum gallium nitride (AlGaN) semiconductor materials have beendeveloped. Some of these LED devices have high light output, highradiance and have a light-reflecting surface that can reflect at least50% of the light incident upon the device. The reflective surface of theLED can be a specular reflector or a diffuse reflector. Typically, thereflective surface of the LED is a specular reflector. Radiance outputsclose to 7000 watts per square meter per steradian and total outputs ofapproximately 0.18 watt from a single packaged device are possible.Light outputs per unit area can exceed 0.045 watt/mm². As such, severalnew applications relating to illumination systems have become possible.Advantages such as spectral purity, reduced heat, and fast switchingspeed all provide motivation to use LEDs and semiconductor lasers toreplace fluorescent, incandescent and arc lamp sources.

FIG. 2B illustrates a cross-sectional view of a recently developed typeof LED 40 that has an emitting layer 46 located below both a transparenttop electrode 43 and a second transparent layer 44. Emitting layer 46emits light rays 45 when an electric current is passed through thedevice 40. Below the emitting layer 46 is a reflecting layer 47 thatalso serves as a portion of the bottom electrode. Electrical contacts 41and 42 provide a pathway for electrical current to flow through thedevice 40. It is a recent new concept to have both electrical contacts41 and 42 on the backside of the LED opposite the emitting surface.Typical prior LED designs placed one electrode on top of the device,which interfered with the light output from the top surface and resultedin devices with low reflectivity. The reflecting layer 47 allows the LEDto be both a light emitter and a light reflector. Lumileds Lighting LLC,for example, produces highly reflective green, blue and ultraviolet LEDdevices of this type. It is expected that highly reflective red andinfrared LEDs with high outputs and high radiance will also eventuallybe developed. However, even the new green, blue and ultraviolet galliumnitride, indium gallium nitride and aluminum gallium nitride LEDs do nothave sufficient radiance for many applications.

LEDs that emit green, blue or ultraviolet light have been combined withluminescent materials to convert the green, blue or ultraviolet lightinto light of a different color or range of colors. For example, in U.S.Pat. No. 6,576,930 a partially transparent, luminescent powder composedof yttrium aluminum garnet (YAG) doped with cerium (denoted by thechemical formula Y₃Al₅O₁₂:Ce³⁺ or as YAG:Ce³⁺) is dispersed in anorganic binder. This luminescent material covers the light outputsurfaces of a blue LED. A portion of the blue light (wavelength of420–460 nm) emitted by the LED is converted to yellow light (at awavelength of approximately 580 nm). The remainder of the blue light canpass through the partially transparent material. The combination of blueand yellow light, if mixed in the proper proportions, appears to thehuman eye to be white light. The material YAG:Ce³⁺ in powdered form isone of many types of luminescent materials commonly known as phosphors.

Schematic diagrams of prior art light-emitting devices that incorporateLEDs in combination with phosphor materials are illustrated in crosssection in FIGS. 3A and 3B and in U.S. Pat. No. 6,417,019. In FIG. 3A,light-emitting device 60 includes an LED source 64 that is coated with aphosphor layer 66. The phosphor layer 66 converts a portion of the LEDlight into light of another wavelength. The light-emitting device 60emits light both from the LED source and from the phosphor layer. Areflecting cup 68 restricts the light output distribution from the LEDsource and the phosphor layer so that the emitted light does not radiatein all directions. However, the reflecting cup does not recycle any ofthe emitted light back to the LED source and does not increase theeffective brightness of the source.

FIG. 3B illustrates the cross section of another light-emitting device80 containing an LED source 84 and phosphor layer 86. The phosphor layer86 substantially fills a reflecting cup 88 and converts a portion of theLED light into light of another wavelength. The reflecting cup 88restricts the light output distribution from the LED source and thephosphor. However, the reflecting cup 88 does not recycle any of theemitted light back to the LED source 84 and does not increase theeffective brightness of the source.

LEDs, including inorganic light-emitting diodes and organiclight-emitting diodes, and the combination of an LED and a luminescentmaterial all emit incoherent light. Semiconductor laser light sources,such as edge-emitting laser diodes and vertical cavity surface emittinglasers, generally emit coherent light. However, semiconductor laserlight sources can be combined with luminescent materials such asphosphors to produce a light source that emits incoherent light.Coherent semiconductor laser light sources typically have higherbrightness than incoherent light sources, but semiconductor laser lightsources are not suitable for many applications such as displays due tothe formation of undesirable speckle light patterns that result from thecoherent nature of the light.

It would be highly desirable to develop incoherent illumination systemsbased on LEDs or semiconductor lasers that utilize both wavelengthconversion and light recycling to increase the illumination systembrightness. Possible applications include projection displays,flat-panel displays, avionics displays, automotive lighting, residentiallighting, commercial lighting and industrial lighting.

SUMMARY OF THE INVENTION

The embodiments of this invention are comprised of a light source thatemits light of a first wavelength range, a wavelength conversion layer,a light-recycling envelope and a light output aperture. The presentinvention combines the concept of recycling light back to the lightsource to enhance brightness with the added element of a wavelengthconversion layer, which converts a portion of the light of a firstwavelength range emitted by the light source into light of a secondwavelength range, different than the light of a first wavelength range.To determine the brightness enhancement of an illumination system due tolight recycling, the output brightness of an illumination systemutilizing light recycling must be compared to the intrinsic brightnessof a reference illumination system that does not utilize recycling. Thereference brightness is either (a) the maximum intrinsic brightness ofthe light source in the absence of light recycling or (b) the maximumcombined intrinsic brightness of the light source and wavelengthconversion layer in the absence of light recycling. In this invention,recycled light refers to light that was emitted by the light source orthe wavelength conversion layer and was subsequently reflected back toeither the light source or the wavelength conversion layer.

In the first embodiment of this invention, the output brightness of theillumination system is measured as the combined exiting brightness ofboth light of a first wavelength range and light of a second wavelengthrange exiting the light output aperture in the presence of alight-recycling envelope. The reference brightness is the maximumintrinsic source brightness of light of a first wavelength range emittedby an LED light source when light recycling is not utilized. Thereference area utilized to measure the reference brightness is the totallight-emitting area A_(S) of the light source.

In the second embodiment of this invention, the output brightness of theillumination system is measured as the combined exiting brightness ofboth light of a first wavelength range and light of a second wavelengthrange exiting the light output aperture in the presence of alight-recycling envelope. The reference brightness is the maximumcombined intrinsic brightness of light of a first wavelength range andlight of a second wavelength range emitted by an LED light source and awavelength conversion layer operating in combination when lightrecycling is not utilized. The reference area utilized to measure thereference brightness is the maximum cross-sectional area A_(E) of thelight-recycling envelope.

In the third embodiment of this invention, the output brightness of theillumination system is measured as the exiting brightness of light of asecond wavelength range exiting the light output aperture in thepresence of a light-recycling envelope. The reference brightness is themaximum intrinsic brightness of light of a second wavelength rangeemitted by a semiconductor laser light source and a wavelengthconversion layer operating in combination when light recycling is notutilized. The reference area utilized to measure the referencebrightness is the maximum cross-sectional area A_(E) of thelight-recycling envelope.

The three embodiments of this invention are now summarized in greaterdetail.

The first embodiment of this invention is an illumination systemcomprising: (a) a light source, wherein the light source comprises atleast one light-emitting diode that emits light of a first wavelengthrange, wherein the at least one light-emitting diode is furthercomprised of an emitting layer that emits the light of a firstwavelength range and a reflecting layer that reflects light, wherein thereflectivity of the reflecting layer is reflectivity R_(S), wherein thetotal light-emitting area of the light source is area A_(S) and whereinthe fight of a first wavelength range emitted by the light source has amaximum intrinsic source radiance and a maximum intrinsic sourceluminance; (b) a wavelength conversion layer, wherein the wavelengthconversion layer converts a portion of the light of a first wavelengthrange into light of a second wavelength range, different from the lightof a first wavelength range; (c) a light-recycling envelope, wherein thelight-recycling envelope is separate from the wavelength conversionlayer, wherein the light-recycling envelope at least partially enclosesthe light source and the wavelength conversion layer, wherein thelight-recycling envelope has reflectivity R_(E) and wherein thelight-recycling envelope reflects and recycles part of the light of afirst wavelength range and part of the light of a second wavelengthrange back to the reflecting layer of the at least one light-emittingdiode and to the wavelength conversion layer; and (d) at least one lightoutput aperture, wherein the at least one light output aperture islocated in a surface of the light-recycling envelope, wherein the totallight output aperture area is area A_(O), wherein the area A_(O) is lessthan the area A_(S), wherein the light source and the wavelengthconversion layer and the light-recycling envelope direct at least afraction of the light of a first wavelength range and at least afraction of the light of a second wavelength range out of thelight-recycling envelope through the at least one light output apertureand wherein the fraction of the light of a first wavelength range andthe fraction of the light of a second wavelength range exit the at leastone light output aperture as incoherent light having a combined exitingradiance and a combined exiting luminance. Under some conditionsutilizing light recycling, the combined exiting radiance exiting the atleast one light-output aperture of the illumination system is greaterthan the maximum intrinsic source radiance and/or the combined exitingluminance exiting the at least one light-output aperture of theillumination system is greater than the maximum intrinsic sourceluminance.

The second embodiment of this invention is an illumination systemcomprising: (a) a light source, wherein the light source comprises atleast one light-emitting diode that emits light of a first wavelengthrange, wherein the light-emitting diode is further comprised of anemitting layer that emits the light of a first wavelength range and areflecting layer that reflects light and wherein the reflectivity of thereflecting layer is reflectivity R_(S); (b) a wavelength conversionlayer, wherein the wavelength conversion layer converts a portion of thelight of a first wavelength range into light of a second wavelengthrange, different from the light of a first wavelength range and whereinthe light source and the wavelength conversion layer operating incombination have a maximum combined intrinsic radiance and a maximumcombined intrinsic luminance; (c) a light-recycling envelope, whereinthe light-recycling envelope is separate from the wavelength conversionlayer, wherein the light-recycling envelope at least partially enclosesthe light source and the wavelength conversion layer, wherein themaximum cross-sectional area of the light-recycling envelope is areaA_(E), wherein the light-recycling envelope has reflectivity R_(E) andwherein the light-recycling envelope reflects and recycles part of thelight of a first wavelength range and part of the light of a secondwavelength range back to the reflecting layer of the light source and tothe wavelength conversion layer; and (d) at least one light outputaperture, wherein the at least one light output aperture is located in asurface of the light-recycling envelope, wherein the total light outputaperture area is area A_(O), wherein the area A_(O) is less than thearea A_(E) and wherein the light source and the wavelength conversionlayer and the light-recycling envelope direct at least a fraction of thelight of a first wavelength range and at least a fraction of the lightof a second wavelength range out of the light-recycling envelope throughthe at least one light output aperture and wherein the fraction of thelight of a first wavelength range and the fraction of the light of asecond wavelength range exit the at least one light output aperture asincoherent light that has a combined exiting radiance and a combinedexiting luminance. Under some conditions utilizing light recycling, thecombined exiting radiance exiting the at least one light-output apertureof the illumination system is greater than the maximum combinedintrinsic radiance and/or the combined exiting luminance exiting the atleast one light-output aperture of the illumination system is greaterthan the maximum combined intrinsic luminance.

The third embodiment of this invention is an illumination systemcomprising: (a) a light source, wherein the light source comprises atleast one semiconductor laser that emits light of a first wavelengthrange; (b) a wavelength conversion layer, wherein the wavelengthconversion layer converts a portion of the light of a first wavelengthrange into light of a second wavelength range, different from the lightof a first wavelength range and wherein the light source and thewavelength conversion layer operating in combination have a maximumcombined intrinsic radiance of light of a second wavelength range and amaximum combined intrinsic luminance of light of a second wavelengthrange; (c) a light-recycling envelope, wherein the light-recyclingenvelope is separate from the wavelength conversion layer, wherein thelight-recycling envelope at least partially encloses the light sourceand the wavelength conversion layer, wherein the maximum cross-sectionalarea of the light-recycling envelope is area A_(E), wherein thelight-recycling envelope has reflectivity R_(E) and wherein thelight-recycling envelope reflects and recycles part of the light of afirst wavelength range and part of the light of a second wavelengthrange back to the wavelength conversion layer; and (d) at least onelight output aperture, wherein the at least one light output aperture islocated in a surface of the light-recycling envelope, wherein the totallight output aperture area is area A_(O), wherein the area A_(O) is lessthan the area A_(E) and wherein the wavelength conversion layer and thelight-recycling envelope direct at least a fraction of the light of asecond wavelength range out of the light-recycling envelope through theat least one light output aperture and wherein the fraction of the lightof a second wavelength range exits the at least one light outputaperture as incoherent light having an exiting radiance of light of asecond wavelength range and an exiting luminance of light of a secondwavelength range. Under some conditions utilizing light recycling, theexiting radiance of light of a second wavelength range exiting the atleast one light-output aperture of the illumination system is greaterthan the maximum combined intrinsic radiance of light of a secondwavelength range and/or the exiting luminance of light of a secondwavelength range exiting the at least one light-output aperture of theillumination system is greater than the maximum combined intrinsicluminance of light of a second wavelength range.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention, as well as otherobjects and advantages thereof not enumerated herein, will becomeapparent upon consideration of the following detailed description andaccompanying drawings, wherein:

FIGS. 1A and 1B are cross-sectional side views of conventional opticalsystems of the prior art.

FIGS. 2A and 2B are cross-sectional views of prior art light sourcesthat have both reflecting and emitting surfaces.

FIGS. 3A and 3B are cross-sectional views of prior art light-emittingdiode illumination systems.

FIG. 4A is a top external view of an illumination system that has onelight-emitting diode.

FIG. 4B is a cross-sectional side view in the I—I plane of theillumination system shown in FIG. 4A.

FIG. 4C is a cross-sectional side view in the II—II plane of theillumination system shown in FIG. 4A.

FIG. 4D is a cross-sectional side view in the II—II plane of theillumination system shown in FIG. 4A and illustrates representativelight rays.

FIG. 5A is a top external view of one embodiment of this invention thathas one light-emitting diode and a wavelength conversion layer.

FIG. 5B is a cross-sectional side view in the I—I plane of theillumination system shown in FIG. 5A.

FIG. 5C is a cross-sectional side view in the II—II plane of theillumination system shown in FIG. 5A.

FIGS. 5D, 5E, 5F and 5G are cross-sectional side views in the II—IIplane of the illumination system shown in FIGS. 5A and 5C and illustraterepresentative light rays.

FIG. 6 is a cross-sectional side view of another embodiment of thisinvention that further comprises a dichroic mirror.

FIG. 7 is a cross-sectional side view of another embodiment of thisinvention that further comprises a light-collimating element.

FIG. 8A is a cross-sectional side view of another embodiment of thisinvention that has two light-emitting diodes and a wavelength conversionlayer.

FIG. 8B is a cross-sectional side view of another embodiment of thisinvention that has three light-emitting diodes and a wavelengthconversion layer.

FIGS. 9A and 9B are cross-sectional side views of other embodiments ofthis invention where the wavelength conversion layer is a coating.

FIG. 9C is a cross-sectional side view of another embodiment of thisinvention where the wavelength conversion layer substantially fills thelight-recycling envelope.

FIGS. 10A and 10B are cross-sectional side views of another embodimentof this invention that further comprises a light guide.

FIG. 10C is a cross-sectional side view of another embodiment of thisinvention that incorporates three light guides and three light-emittingdiodes.

FIG. 11A is a top external view of another embodiment of this inventionthat has one light-emitting diode and a wavelength conversion layer.

FIG. 11B is a cross-sectional side view in the I—I plane of theillumination system shown in FIG. 11A.

FIGS. 11C, 11D, 11E and 11F are cross-sectional side views in the I—Iplane of the illumination system shown in FIGS. 11A and 11B andillustrate representative light rays.

FIG. 12 is a cross-sectional side view of another embodiment of thisinvention that further comprises a dichroic mirror.

FIG. 13 is a cross-sectional side view of another embodiment of thisinvention that further comprises a light-collimating element.

FIG. 14 is a cross-sectional side view of another embodiment of thisinvention that has three light-emitting diodes and a wavelengthconversion layer.

FIG. 15 is cross-sectional side view of another embodiment of thisinvention that further comprises a light guide.

FIG. 16 is a cross-sectional side view of another embodiment of thisinvention that incorporates three light guides and three light-emittingdiodes.

FIGS. 17, 18 and 19 are cross-sectional side views of other embodimentsof this invention where the wavelength conversion layer is a coating.

FIG. 20A is a top external view of another embodiment of this inventionthat has one semiconductor laser and a wavelength conversion layer.

FIG. 20B is a cross-sectional side view in the I—I plane of theillumination system shown in FIG. 20A.

FIG. 20C is a cross-sectional side view in the I—I plane of theillumination system shown in FIGS. 20A and 20B and illustratesrepresentative light rays.

FIG. 21 is a cross-sectional side view of another embodiment of thisinvention that further comprises a dichroic mirror.

FIG. 22 is cross-sectional side view of another embodiment of thisinvention that further comprises a light guide.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The preferred embodiments of the present invention will be betterunderstood by those skilled in the art by reference to the aboveFIGURES. The preferred embodiments of this invention illustrated in theFIGURES are not intended to be exhaustive or to limit the invention tothe precise form disclosed. The FIGURES are chosen to describe or tobest explain the principles of the invention and its applicable andpractical use to thereby enable others skilled in the art to bestutilize the invention.

The embodiments of this invention are comprised of a light source, awavelength conversion layer, a light-recycling envelope and at least onelight output aperture located in the surface of the light-recyclingenvelope.

The preferred light source of this invention comprises at least onelight-emitting diode (LED) or at least one semiconductor laser.Preferred LEDs are inorganic light-emitting diodes and organiclight-emitting diodes (OLEDs) that both emit light and reflect light.More preferred LEDs are inorganic light-emitting diodes due to theirhigher light output brightness. Preferred semiconductor lasers areedge-emitting diode lasers and vertical cavity surface-emitting lasers.

Various illumination systems that utilize LEDs are illustrated in FIGS.4–19. An LED depicted in FIGS. 4–19 may be any LED that both emits lightand reflects light. Examples of LEDs that both emit and reflect lightinclude inorganic light-emitting diodes and OLEDs. Inorganiclight-emitting diodes can be fabricated from materials containinggallium nitride, aluminum gallium nitride, indium gallium nitride,aluminum nitride, aluminum indium gallium phosphide, gallium arsenide,indium gallium arsenide or indium gallium arsenide phosphide, forexample, but are not limited to such materials. OLEDs may be constructedfrom a variety of light-emitting organic small molecules or polymers.Appropriate small molecules include, for example, tris.(8-hydroxyquinoline) aluminum(III), which can be abbreviated as Alq₃,and certain types of chelates, oxadiazoles, imidazoles, benzidines andtriarylamines, but are not limited to such materials. Appropriatepolymers include, for example, poly(ethylene dioxythiophene) andpoly(styrene sulfonate).

For purposes of simplifying the FIGURES, each LED in FIGS. 4–19 isillustrated in an identical manner and each LED is shown as beingcomprised of two elements, an emitting layer that emits light and areflecting layer that reflects light. Note that typical LEDs arenormally constructed with more than two elements, but for the purposesof simplifying FIGS. 4–19, the additional elements are not shown. Someof the embodiments of this invention may contain two or more LEDs.Although each LED in FIGS. 4–19 is illustrated in an identical manner,it is within the scope of this invention that multiple LEDs in anembodiment may not all be identical. For example, if an embodiment ofthis invention has a plurality of LEDs, it is within the scope of thisinvention that some of the LEDs may be inorganic light-emitting diodesand some of the LEDs may be OLEDs. As a further example of anillumination system having multiple LEDs, if an embodiment of thisinvention has a plurality of LEDs, it is also within the scope of thisinvention that some of the LEDs may emit different colors of light.Example LED colors include, but are not limited to, wavelengths in theinfrared, visible and ultraviolet regions of the optical spectrum. Forexample, one or more of the LEDs in a light-recycling envelope may bered LEDs, one or more of the LEDs may be green LEDs and one or more ofthe LEDs may be blue LEDs. If an embodiment, for example, contains red,green and blue LEDS, then the red, green and blue LEDs may be poweredconcurrently to produce a single composite output color such as whitelight. Alternatively, the red, green and blue LEDs in this example mayeach be powered at different times to produce different colors indifferent time periods.

Preferred LEDs have at least one reflecting layer that reflects lightincident upon the LED. The reflecting layer of the LED may be either aspecular reflector or a diffuse reflector. Typically, the reflectinglayer is a specular reflector. Preferably the reflectivity R_(S) of thereflecting layer of the LED is at least 50%. More preferably, thereflectivity R_(S) is at least 70%. Most preferably, the reflectivityR_(S) is at least 90%.

Each LED in FIGS. 4–9, 11–14 and 17–19 is illustrated with an emittinglayer facing the interior of the light-recycling envelope and areflecting layer positioned behind the emitting layer and adjacent tothe inside surface of the light-recycling envelope. In thisconfiguration, light can be emitted from all surfaces of the emittinglayer that are not in contact with the reflecting layer. It is alsowithin the scope of this invention that a second reflecting layer can beplaced on the surface of the emitting layer facing the interior of thelight-recycling envelope. In the latter example, light can be emittedfrom the side surfaces of the emitting layer that do not contact eitherreflecting layer. A second reflecting layer is especially important forsome types of LEDs that have an electrical connection on the top surfaceof the emitting layer since the second reflecting layer can improve theoverall reflectivity of the LED.

The total light-emitting area of the light source is area A_(S). Ifthere is more than one LED within a single light-recycling envelope, thetotal light-emitting area A_(S) of the light source is the totallight-emitting area of all the LEDs in the light-recycling envelope.

The light source, whether comprising one LED or a plurality of LEDs, hasa maximum intrinsic source radiance that depends on the light sourcedesign and the driving electrical power applied to the light source. Themaximum intrinsic source radiance is determined in the following manner.First, the radiance is measured for each LED in the light source (or forequivalent reference LEDs for each LED in the light source) when thelight-recycling envelope is not present and when no other LED isdirecting light to the LED under measurement. The measurements are donewith each LED powered at the same level as in the illumination systemand are done as a function of emitting angle. From these radiancemeasurements, a maximum radiance value can be determined for all theLEDs. This maximum value is defined as the maximum intrinsic sourceradiance.

The light source for the illuminations systems in FIGS. 20–22 is atleast one semiconductor laser. Semiconductor lasers includeedge-emitting diode lasers, which have a horizontal cavity (theprincipal axis of the cavity is parallel to the plane of thesemiconductor wafer or chip) and vertical end mirrors (perpendicular tothe plane of the semiconductor wafer or chip). Semiconductor lasers alsoinclude vertical cavity surface emitting lasers (VCSELs), which have avertical cavity (the principal axis of the cavity is perpendicular tothe plane of the semiconductor wafer or chip) and horizontal mirrors(parallel to the plane of the semiconductor wafer or chip). The lightoutput area of a semiconductor laser is usually small. Recycling lightback to a semiconductor laser located in a light-recycling envelope ofan illumination system will generally have a relatively small effect onthe output brightness of the illumination system. For light-recyclingenvelopes that contain semiconductor lasers and no LEDs, the predominantlight recycling mechanism is light recycling back to the wavelengthconversion layer.

The light of a first wavelength range emitted by the light source, wherethe light source at least one LED or at least one semiconductor laser,is preferably greater that 200 nanometers in wavelength and less than3000 nanometers in wavelength. More preferably, the light of a firstwavelength range is greater than 200 nanometers in wavelength and lessthan 450 nanometers in wavelength.

The wavelength conversion layer of this invention converts a portion ofthe light of a first wavelength range into light of a second wavelengthrange, different from the light of a first wavelength range. The lightof a second wavelength range has longer wavelengths than the light of afirst wavelength range.

The wavelength conversion layer is comprised of a powdered phosphormaterial, a quantum dot material, a luminescent dopant material or aplurality of such materials. The wavelength conversion layer may furthercomprise a transparent host material into which the phosphor material,the quantum dot material or the luminescent dopant material isdispersed.

Powdered phosphor materials are typically optical inorganic materialsdoped with ions of lanthanide (rare earth) elements or, alternatively,ions such as chromium, titanium, vanadium, cobalt or neodymium. Thelanthanide elements are lanthanum, cerium, praseodymium, neodymium,promethium, samarium, europium, gadolinium, terbium, dysprosium,holmium, erbium, thulium, ytterbium and lutetium. Optical inorganicmaterials include, but are not limited to, sapphire (Al₂O₃), galliumarsenide (GaAs), beryllium aluminum oxide (BeAl₂O₄), magnesium fluoride(MgF₂), indium phosphide (InP), gallium phosphide (GaP), yttriumaluminum garnet (YAG or Y₃Al₅O₁₂), terbium-containing garnet,yttrium-aluminum-lanthanide oxide compounds,yttrium-aluminum-lanthanide-gallium oxide compounds, yttrium oxide(Y₂O₃), calcium or strontium or barium halophosphates(Ca,Sr,Ba)₅(PO₄)₃(Cl,F), the compound CeMgAl₁₁O₁₉, lanthanum phosphate(LaPO₄), lanthanide pentaborate materials ((lanthanide)(Mg,Zn)B₅O₁₀),the compound BaMgAl₁₀O₁₇, the compound SrGa₂S₄, the compounds(Sr,Mg,Ca,Ba)(Ga,Al,In)₂S₄, the compound SrS, the compound ZnS andnitridosilicate. There are several exemplary phosphors that can beexcited at 250 nm or thereabouts. An exemplary red emitting phosphor isY₂O₃:Eu³⁺. An exemplary yellow emitting phosphor is YAG:Ce³⁺. Exemplarygreen emitting phosphors include CeMgAl₁₁O₁₉:Tb³⁺,((lanthanide)PO₄:Ce³⁺,Tb³⁺) and GdMgB₅O₁₀:Ce³⁺,Tb³⁺. Exemplary blueemitting phosphors are BaMgAl₁₀O₁₇:Eu²⁺ and (Sr,Ba,Ca)₅(PO₄)₃Cl:Eu²⁺.For longer wavelength LED excitation in the 400–450 nm wavelength regionor thereabouts, exemplary optical inorganic materials include yttriumaluminum garnet (YAG or Y₃Al₅O₁₂), terbium-containing garnet, yttriumoxide (Y₂O₃), YVO₄, SrGa₂S₄, (Sr,Mg,Ca,Ba)(Ga,Al,In)₂S₄, SrS, andnitridosilicate. Exemplary phosphors for LED excitation in the 400–450nm wavelength region include YAG:Ce³⁺, YAG:Ho³⁺, YAG:Pr³⁺, SrGa₂S₄:Eu²⁺,SrGa₂S₄:Ce³⁺, SrS:Eu²⁺ and nitridosilicates doped with Eu²⁺.

Quantum dot materials are small particles of inorganic semiconductorshaving particle sizes less than about 40 nanometers. Exemplary quantumdot materials include, but are not limited to, small particles of CdS,CdSe, ZnSe, InAs, GaAs and GaN. Quantum dot materials can absorb lightat one wavelength and then re-emit the light at different wavelengthsthat depend on the particle size, the particle surface properties, andthe inorganic semiconductor material. Sandia National Laboratories hasdemonstrated white light generation using 2-nanometer CdS quantum dotsexcited with near-ultraviolet LED light. Efficiencies of approximately60% were achieved at low quantum dot concentrations dispersed in a largevolume of transparent host material. Because of their small size,quantum dot materials dispersed in transparent host materials exhibitlow optical backscattering.

Luminescent dopant materials include, but are not limited to, organiclaser dyes such as coumarin, fluorescein, rhodamine and perylene-baseddyes. Other types of luminescent dopant materials are lanthanidedopants, which can be incorporated into polymer materials. Thelanthanide elements are lanthanum, cerium, praseodymium, neodymium,promethium, samarium, europium, gadolinium, terbium, dysprosium,holmium, erbium, thulium, ytterbium and lutetium. An exemplarylanthanide element is erbium.

The transparent host materials include polymer materials and inorganicmaterials. The polymer materials include, but are not limited to,acrylates, polystyrene, polycarbonate, fluoroacrylates,perfluoroacrylates, fluorophosphinate polymers, fluorinated polyimides,polytetrafluoroethylene, fluorosilicones, sol-gels, epoxies,thermoplastics, thermosetting plastics and silicones. Fluorinatedpolymers are especially useful at ultraviolet wavelengths less than 400nanometers and infrared wavelengths greater than 700 nanometers owing totheir low light absorption in those wavelength ranges. Exemplaryinorganic materials include, but are not limited to, silicon dioxide,optical glasses and chalcogenide glasses.

A single type of powdered phosphor material, quantum dot material orluminescent dopant material may be incorporated in the wavelengthconversion layer or a mixture of powdered phosphor materials, quantumdot materials and/or luminescent dopant materials may be incorporatedinto the wavelength conversion layer. Utilizing a mixture of more thanone such material is advantageous if a broad spectral emission range isdesired for the light of a second wavelength range.

The wavelength conversion layer may be transparent, translucent orpartially reflecting. The optical properties of the wavelengthconversion layer depend strongly on the materials utilized for thelayer. Wavelength conversion layers containing particles that are muchsmaller than the wavelengths of visible light and that are dispersed ina transparent host material may be highly transparent or translucentwith only a small amount of light scattering. Wavelength conversionlayers that contain particles that are approximately equal to or largerthan the wavelengths of visible light will usually scatter lightstrongly. Such materials will be partially reflecting. If the wavelengthconversion layer is partially reflecting, it is preferred that the layerbe made thin enough so that it transmits at least part of the lightincident upon the layer.

The wavelength conversion layer may be applied as a coating on theinside surfaces of the light-recycling envelope, may be applied as acoating on the light output surfaces of an LED, or may partially fill,substantially fill or completely fill the interior volume of thelight-recycling envelope.

By placing the wavelength conversion layer in contact with the emittinglayer of an LED, the difference in refractive index between the emittinglayer and the environment external to the emitting layer will be reducedrelative to having air at the interface of the emitting layer. Reducingthe refractive index difference can reduce total internal reflection oflight of a first wavelength range generated inside the emitting layerand increase the efficiency of light emission from the emitting layer.This effect can result in an overall increase in the efficiency of theillumination system. The highest efficiency of light emission from theemitting layer will occur if the effective refractive index of thewavelength conversion layer is equal to or greater than the refractiveindex of the emitting layer.

If necessary, the effective refractive index of the wavelengthconversion layer can be increased by incorporating ultrafine powders ofhigh index materials into the wavelength conversion layer. Preferably,the ultrafine powders are made from materials having a bulk index ofrefraction greater than 1.60. Ultrafine powders are powders withparticle sizes less than about 300 nanometers. Exemplary ultrafinepowders can be made from materials such as, for example, tin oxide,titanium oxide, zinc oxide, cerium oxide and antimony pentoxide.

The light-recycling envelope of this invention is a light-reflectingelement that at least partially encloses the light source and thewavelength conversion layer. The light-recycling envelope is an elementseparate from the wavelength conversion layer. The light-recyclingenvelope may be any three-dimensional surface that encloses an interiorvolume. For example, the surface of the light-recycling envelope may bein the shape of a cube, a rectangular three-dimensional surface, asphere, a spheroid, an ellipsoid, an arbitrary three-dimensionalfacetted surface or an arbitrary three-dimensional curved surface.Preferably the three-dimensional shape of the light-recycling envelopeis a facetted surface with flat sides in order to facilitate theattachment of LEDs to the inside surfaces of the envelope. Preferablethree-dimensional shapes have a cross-section that is a square, arectangle or a polygon.

The light-recycling envelope reflects and recycles part of the light ofa first wavelength range and part of the light of a second wavelengthrange back to the light source and to the wavelength conversion layer.Preferably the reflectivity R_(E) of the inside surfaces of thelight-recycling envelope is at least 50%. More preferably, thereflectivity R_(E) is at least 70%. Most preferably, the reflectivityR_(E) is at least 90%. Ideally, the reflectivity R_(E) should be asclose to 100% as possible in order to maximize the efficiency andexiting brightness of the illumination system.

The light-recycling envelope may be fabricated from a bulk material thatis intrinsically reflective. A bulk material that is intrinsicallyreflective may be a diffuse reflector or a specular reflector.Preferably a bulk material that is intrinsically reflective is a diffusereflector. Diffuse reflectors reflect light rays in random directionsand prevent reflected light from being trapped in cyclically repeatingpathways. Specular reflectors reflect light rays where the angle ofincidence is equal to the angle of reflection.

Alternatively, if the light-recycling envelope is not fabricated from anintrinsically reflective material, the interior surfaces of thelight-recycling envelope must be covered with a reflective coating. Thereflective coating may be a specular reflector, a diffuse reflector or adiffuse reflector that is backed with a specular reflecting layer.Diffuse reflectors typically need to be relatively thick (a fewmillimeters) in order to achieve high reflectivity. The thickness of adiffuse reflector needed to achieve high reflectivity can be reduced ifa specular reflector is used as a backing to the diffuse reflector.

Diffuse reflectors can be made that have very high reflectivity (forexample, greater than 95% or greater than 98%). However, diffusereflectors with high reflectivity are generally quite thick. Forexample, diffuse reflectors with reflectivity greater than 98% aretypically several millimeters thick. Examples of diffuse reflectorsinclude, but are not limited to, fluoropolymer materials such asSpectralon™ from Labsphere, Inc. and polytetrafluoroethylene film frommanufacturers such as Fluorglas (sold under the trade name Furon™), W.L. Gore and Associates, Inc. (sold under the trade name DR™), or E. I.du Pont de Nemours & Company (sold under the trade name of Teflon™),films of barium sulfate, porous polymer films containing tiny airchannels such as polyethersulfone and polypropylene filter materialsmade by Pall Gelman Sciences, and polymer composites utilizingreflective filler materials such as, for example, titanium dioxide. Anexample of the latter polymer composite material is titanium dioxidefilled ABS (acrylonitrile-butadiene-styrene terpolymer) produced by RTP.In the case that a polymer composite material is employed as areflective material, such as titanium dioxide filled ABS, thelight-recycling envelope can be formed from the polymer compositematerial and a separate light-reflecting layer is not needed on theinterior surfaces of the light-recycling envelope.

If the inside surfaces of a light-recycling envelope are coated with awavelength conversion layer containing, for example, a powdered phosphormaterial, the wavelength conversion layer itself may also be apartially-reflecting, diffuse reflector. If the light-recycling envelopeis coated with a wavelength conversion layer, then the wavelengthconversion layer will be selected not to interfere with the reflectivityof the light-recycling envelope. In addition, the light-recyclingenvelope will be selected not to interfere with the wavelengthconversion of the wavelength conversion layer.

Most specular reflective materials have reflectivity ranging from about80% to about 98.5%. Examples of specular reflective materials include,but are not limited to, Silverlux™, a product of 3M Corporation, andother carrier films of plastic that have been coated with a thinmetallic layer such as silver, aluminum or gold. The thickness of themetallic coating may range from about 0.05 micrometers to about 0.1millimeter, depending on the materials used and the method ofmanufacturing the metal coating. Other examples of specular reflectivefilms that have high reflectivity include photonic bandgap reflectivematerials and Vikuiti™ ESR (Enhanced Specular Reflector) made by 3MCorporation. The ESR film has a reflectivity of greater than 98% acrossthe visible light spectrum.

The interior volume of the light-recycling envelope that is not occupiedby the wavelength conversion layer and the light source may be occupiedby a vacuum, may be filled with a light transmitting gas or may befilled or partially filled with a transparent or semi-transparent solidseparate from the wavelength conversion material. Any gas or solid thatfills or partially fills the light-recycling envelope should transmitboth the light of a first wavelength range and the light of a secondwavelength range. Examples of light-transmitting gases are air, nitrogenand inert gases such as argon. Examples of transparent solids includeglasses such as silicon dioxide or plastics such aspolymethylmethacrylate, polystyrene, polycarbonate or asilicone-containing material.

The light-recycling envelope has at least one light output aperture. Thelight source and the wavelength conversion layer and the light-recyclingenvelope direct at least a fraction of the light of a first wavelengthrange and at least a fraction of the light of a second wavelength rangeout of the light-recycling envelope through the at least one lightoutput aperture as incoherent light. The total light output aperturearea is area A_(O). If there is more than one output aperture in thelight-recycling envelope, A_(O) refers to the combined area of all theoutput apertures. An output aperture may have any shape including, butnot limited to, a square, a rectangle, a polygon, a circle, an ellipse,an arbitrary facetted shape or an arbitrary curved shape.

An illustrative example of an illumination system that utilizes lightrecycling is illumination system 100 shown FIGS. 4A, 4B, 4C and 4D. FIG.4A is a top exterior view of illumination system 100 showing the outeredge of a light-recycling envelope 102 and a light output aperture 104.FIG. 4B is a cross-sectional view along the I—I plane indicated in FIG.4A. FIG. 4C is a cross-sectional view along the II—II plane indicated inFIG. 4A. The II—II plane passes through the light output aperture 104and LED 106. FIG. 4D shows the paths of some representative light raysemitted from LED 106. Illumination system 100 of FIG. 3 does not containany wavelength conversion layer.

The cubical three-dimensional shape of the surface of thelight-recycling envelope 102, the square cross-sectional shape of thelight-recycling envelope 102 and the square shape of the light outputaperture 104 are illustrative examples used for ease of understanding ofthe descriptions. It should also be noted that the drawing is merely arepresentation of the structure; the actual and relative dimensions maybe different.

As noted previously, the light-recycling envelope 102 may be anythree-dimensional surface that encloses an interior volume. For example,the surface of the light-recycling envelope may be in the shape of acube, a rectangular three-dimensional surface, a sphere, a spheroid, anellipsoid, an arbitrary three-dimensional facetted surface or anarbitrary three-dimensional curved surface. The only requirement for thethree-dimensional shape of the light-recycling envelope is that afraction of any light emitted from an LED within the light-recyclingenvelope must also exit from the light output aperture of thelight-recycling envelope within a finite number of reflections withinthe light-recycling envelope, i.e. there are no reflective dead spotswithin the light-recycling envelope where the light emitted from the LEDwill endlessly reflect without exiting the light-recycling envelopethrough the light output aperture. The cross-section of thelight-recycling envelope 102, such as the one shown in FIG. 4C, may haveany shape, both regular and irregular, depending on the shape of thethree-dimensional surface. Other examples of possible cross-sectionalshapes include a rectangle, a taper, a polygon, a circle, an ellipse, anarbitrary facetted shape or an arbitrary curved shape.

In illumination system 100, the inside surfaces of the light-recyclingenvelope 102, except for the area covered by the LED 106 and the areaoccupied by the light output aperture 104, are light reflectingsurfaces. In order to achieve high light reflectivity, thelight-recycling envelope 102 may be fabricated from a bulk material thatis intrinsically reflective or the inside surfaces of thelight-recycling envelope 102 may be covered with a reflective coating.The bulk material or the reflective coating may be a specular reflector,a diffuse reflector or a diffuse reflector that is backed with aspecular reflecting layer. Examples of reflective materials weredescribed previously. Preferably the reflectivity R_(E) of the insidesurfaces of the light-recycling envelope 102 that are not occupied bythe LED 106 and the light output aperture 104 is at least 50%. Morepreferably, the reflectivity R_(E) is at least 70%. Most preferably, thereflectivity R_(E) is at least 90%. Ideally, the reflectivity R_(E)should be as close to 100% as possible in order to maximize theefficiency and output brightness of the illumination system.

The square cross-sectional shape of illumination system 100 shown inFIG. 4C has a first side containing the light output aperture 104, asecond side, a third side and a fourth side. The first side is oppositeand parallel to the third side. The second side is opposite and parallelto the fourth side. The first side and third side are perpendicular tothe second side and fourth side. The four sides of the illuminationsystem shown in cross-section in FIG. 4C plus the two remaining sides ofthe six-sided cube (not shown in the cross-sectional view) form theinterior of the light-recycling envelope.

The light source for illumination system 100 is LED 106, which ispositioned interior to the fourth side of the illumination system. LED106 emits light of a first wavelength range. LED 106 may be anyinorganic light-emitting diode or an OLED. Preferably, LED 106 is aninorganic light-emitting diode.

LED 106 has a reflecting layer 110 and an emitting layer 108. Thereflecting layer is adjacent to and interior to the fourth side whilethe emitting layer extends into the interior of the light-recyclingenvelope. The reflecting layer 110 may be a specular reflector or adiffuse reflector. In a typical inorganic light-emitting diode, thereflecting layer, if present, is usually a specular reflector. The lightreflectivity of reflecting layer 110 of LED 106 is R_(S). If thereflectivity varies across the area of the reflecting layer, thereflectivity R_(S) is defined as the average reflectivity of thereflecting layer. The reflectivity R_(S) of reflecting layer 110 ispreferably at least 50%. More preferably, the reflectivity R_(S) ofreflecting layer 110 is at least 70%. Most preferably, the reflectivityR_(S) of reflecting layer 110 is at least 90%. Ideally, the reflectivityR_(S) should be as close to 100% as possible in order to maximize theefficiency and output brightness of the illumination system.

The total light-emitting area of the light source is area A_(S). InFIGS. 4A–4D, the light source consists of just one LED, so the totallight-emitting area A_(S) of the light source is the light-emitting areaof LED 106.

The light output from the LED 106, which is light of a first wavelengthrange, has a maximum intrinsic source radiance and a maximum intrinsicsource luminance that depend on the LED design and the drivingelectrical power applied to the LED. The maximum intrinsic sourceradiance and maximum intrinsic source luminance of LED 106 can bedetermined by measuring an identically constructed LED that is notenclosed in a light-recycling envelope.

The light output aperture 104 is in the first side of the illuminationsystem. A fraction of the light coming from the light source and thelight-recycling envelope exits the light output aperture. As noted, theaperture may have any shape including, but not limited to, a square, arectangle, a polygon, a circle, an ellipse, an arbitrary facetted shapeor an arbitrary curved shape. The total light output aperture area isarea A_(O), which in this case is just the area of the single lightoutput aperture 104. If the illumination system has more than one lightoutput aperture, the area A_(O) is the total area of all the lightoutput apertures.

Light may be emitted from emitting layer 108 of LED 106 through one ormore of the surfaces of emitting layer 108 that do not contactreflecting layer 110. For example, light may be emitted through surface112. Three illustrative examples of light rays emitted through surface112 are shown in FIG. 4D.

In FIG. 4D, a first light ray 114 emitted from the surface 112 ofemitting layer 108 of the LED 106 on the fourth side passes through theinterior of the light-recycling envelope to exit through the lightoutput aperture 104 on the first side without reflecting off thereflecting sides of the light-recycling envelope.

A second light ray 116 emitted from the surface 112 of the emittinglayer 108 of the LED 106 passes through the interior of thelight-recycling envelope and is reflected by the light-recyclingenvelope 102 on the third side. The reflected ray 116 then passesthrough the interior of the light-recycling envelope to exit through thelight output aperture 104 on the first side. This is merely anillustrative example since the second ray 116 can reflect a finitenumber of times from the reflective surfaces of any and all of the sidesbefore exiting the light-recycling envelope through the light outputaperture.

A third light ray 118 emitted from the surface 112 of the emitting layer108 of the LED 106 during a first time period passes through theinterior of the light-recycling envelope 102 and is reflected by thelight-recycling envelope on the second side. The reflected third lightray passes through the interior of the light-recycling envelope and isrecycled back to the light source. The reflected third light ray 118 istransmitted through surface 112 and the emitting layer 108 of the LED106 to reflect off the reflecting layer 110 of the LED 106. The thirdlight ray 118 then is transmitted through the emitting layer 108 of LED106 and through the surface 112 during a second time period, passesthrough the interior of the light-recycling envelope and finally exitsthe light output aperture 104.

Light rays 114 and 116 are not recycled back to the light source. Lightray 118 is recycled back to the light source. Only part of the lightemitted by the light source is recycled back to the light source.

When the third light ray 118 reflects off reflecting layer 110 of LED106 and is transmitted through emitting layer 108 and surface 112 toenter the light-recycling envelope during the second time period, thereflected light ray 118 adds to the light rays concurrently beingemitted by emitting layer 108 of LED 106 during the second time period.The reflected light ray increases the effective source radiance and theeffective source luminance of LED 106 so that the effective sourceradiance and the effective source luminance are then higher than therespective maximum intrinsic source radiance and the maximum intrinsicsource luminance of LED 106 measured in the absence of light recycling.

The brightness (either measured in radiance units or luminance units) ofthe light exiting the light output aperture cannot be greater than theeffective brightness of the light source. However, by recycling a partof the light emitted by the light source back to the light source, theeffective radiance (or luminance) of the light source can be increasedso that the radiance (or luminance) of the light exiting the lightoutput aperture can then be greater than the maximum intrinsic sourceradiance (or luminance) of the light source measured in the absence oflight recycling. Note that when the brightness of the light exiting thelight output aperture of illumination system 100 is compared to themaximum intrinsic brightness of a reference illumination system, the LED106 of the illumination system 100 and the LED of the referenceillumination system are of the same design and are operated at the sameelectrical power.

The third light ray 118 will be unaffected transmitting through theemitting layer 108 of LED 106 whether the emitting layer 108 is emittinglight or not. The third light ray 118 could, alternatively, reflect offthe light-recycling envelope on the first or third side beforereflecting off the reflecting layer 110 of the LED on the fourth side.

This is merely an illustrative example since the third light ray 118 canreflect a finite number of times from the reflective surfaces of any andall the sides before or after reflecting off the reflecting layer 110 ofthe LED, once or any finite number of times, before the third light rayexits the light-recycling envelope through the light output aperture104.

The maximum reflectivity of the inside surfaces of illumination system100 and the resulting maximum radiance and luminance exiting from thelight output aperture 104 is achieved by preferably having the entireinterior surfaces of illumination system 100 be reflective except forthe total area A_(O) of all the apertures in the light-recyclingenvelope. Illumination system 100 has one light output aperture 104having area A_(O). The total inside area of the light-recycling envelopeis A_(T), which includes the area A_(O) and the total light-emittingarea of the light source. The LED light source has a reflecting layer110 having reflectivity R_(S). The total light-emitting area of thelight source is area A_(S). In the example of FIGS. 4A–4D, area A_(S) isthe total light-emitting area of LED 106, but for other examples havingmore than one LED, A_(S) is the total light-emitting area of all theLEDs within the light-recycling envelope. The remaining inside area ofthe light-recycling envelope that is not covered by the totallight-emitting area A_(S) of the LED and the area A_(O) of the outputaperture or apertures is denoted as remaining area A_(R). Preferably theentire remaining area A_(R) of the light-recycling envelope should havea reflective surface of reflectivity R_(E) to maximize the radiance andluminance exiting from the light output aperture or apertures. As notedpreviously, the reflectivity R_(E) is preferably at least 50%. Morepreferably, the reflectivity R_(E) is at least 70%. Most preferably, thereflectivity R_(E) is at least 90%.

Since the area A_(S) and the area A_(R) are not perfect reflectors anddo absorb some of the light during each reflection, the maximumillumination system output efficiency and the maximum output radianceand luminance are achieved by minimizing the number of lightreflections. For a given fixed total light-emitting area A_(S) and agiven fixed total area A_(O) of the light output aperture or apertures,the maximum radiance and luminance emitted from the light outputaperture or apertures is achieved by minimizing the remaining area A_(R)in order to minimize the number of reflections. Usually it is notpossible for the remaining area A_(R) to be zero, however, since it isusually not possible to arrange the one or more LEDs in the illuminationsystem to cover the entire area of the light-recycling envelope that isnot occupied by the light output aperture.

The illumination system 100 can achieve an output radiance or outputluminance that is greater than the respective maximum intrinsic sourceradiance or maximum intrinsic source luminance of the light source onlyif the total light output aperture area A_(O) of the light outputaperture 104 is less than the total light-emitting area A_(S) of thelight source. This area requirement for brightness enhancement can beunderstood from the following theoretical examples. First assume thatthe inside surfaces of a theoretical illumination system have noabsorption losses, i.e. areas A_(S) and A_(R), all have 100%reflectivity. In this case R_(S) and R_(E) are each equal to 100% and nolight will be lost or absorbed inside the illumination system. Alsoassume that the light source emits light in a Lambertian distribution.Note that a Lambertian emitter is an emitter that has a constantradiance or luminance for all emitting angles from −90 degrees to +90degrees.

If the light output aperture area A_(O) is equal to the totallight-emitting area A_(S), then all the light emitted by the source willexit the theoretical illumination system in the same area and will have,in many cases, the same Lambertian distribution. The brightness of thelight exiting the light output aperture will be equal to the intrinsicsource brightness.

If the light output aperture area A_(O) of the theoretical illuminationsystem is larger than the total light-emitting area A_(S), the lightexiting the light output aperture can have the same Lambertiandistribution but will have a brightness that is less than the intrinsicsource brightness due to the output light being spread over a largerarea. The output brightness exiting the light output aperture will belower by a factor of A_(S)/A_(O).

If the light output aperture area A_(O) of the theoretical illuminationsystem is smaller than the total light-emitting area A_(S) and no lightis lost or absorbed inside the illumination system, the light exitingthe light output area can have the same Lambertian distribution but willhave a brightness greater than the intrinsic source brightness due tothe reduced area of the light output aperture. The output brightnessexiting the light output aperture will be greater by a factor ofA_(S)/A_(O). To achieve an output brightness exiting the light outputaperture that is greater than the maximum intrinsic source brightness,it is therefore a requirement that the light output aperture area A_(O)be less than the total light-emitting area A_(S).

However, the area requirement that A_(O) must be less than A_(S) is notthe only requirement needed in order to achieve brightness enhancementin an illumination system. In a typical illumination system, thereflectivity R_(S) and the reflectivity R_(E) will be less than 100%,which will lower the brightness enhancement. Light that does not exitthe light output aperture 104 on the first attempt may be absorbed bythe light source or the light-recycling envelope as it is reflected oneor more times inside the light-recycling envelope. These losses willreduce the output brightness. Therefore, in order to achieve brightnessenhancement in a typical illumination system, R_(S) and R_(E) must berelatively high even if they are not 100%. The preferred values forR_(S) and R_(E) were listed previously.

Furthermore, in a typical illumination system, the light source may notemit light in a wide Lambertian (−90 degrees to +90 degrees) angulardistribution but in a narrower angular distribution. When a light sourceinitially emits light in a narrow angular distribution and when theemitted light then undergoes multiple reflections inside theillumination system, the light exiting the light output aperture willhave a wider angular distribution than the initial angular distribution.The output distribution will be approximately a Lambertian distribution.Expanding the original narrow angular distribution to a wider outputdistribution inside the illumination system also reduces the brightnessof the light exiting the light output aperture. Therefore, in order toachieve brightness enhancement in a typical illumination system, theangular distribution of the light emitted by the light source should beas close to a Lambertian distribution as possible.

The maximum theoretical radiance enhancement or maximum theoreticalluminance enhancement is given by the ratio of the areas A_(S)/A_(O) asshown above. For example, if As equals 20 mm² and A_(O) equals 1 mm²,then the maximum theoretical radiance enhancement or maximum theoreticalluminance enhancement is A_(S)/A_(O) or 20. The maximum value isachieved only if the LED is a Lambertian emitter and only if R_(S) andR_(E) each equal 100%. If the LED is not a perfect Lambertian emitter orif R_(S) and R_(E) are each less than 100%, as is normally the case,brightness enhancement can still be achieved but the enhancement will beless than the maximum theoretical value. In such cases, the area A_(O)may need to be significantly less than A_(S) in order to achieve anoutput brightness that is greater than the maximum intrinsic sourcebrightness. Preferably, the area A_(O) of the light output aperture 104is less than or equal to 50% of the total light-emitting area A_(S) ofthe light source. More preferably, the area A_(O) of the light outputaperture 104 is less than or equal to 30% of the total light-emittingarea A_(S) of the light source. Most preferably, the area A_(O) of thelight output aperture 104 is less than or equal to 10% of the totallight-emitting area A_(S) of the light source. In addition, for someapplications it is desirable that the area A_(O) of the light outputaperture 104 be small and comparable in size to the area of an arc lampsource. For those applications, preferably the area A_(O) of the lightoutput aperture 104 is less than 25 mm² in area. More preferably, thearea A_(O) of the light output aperture 104 is less than 10 mm².

The above example is an illustrative illumination system that does notinclude a wavelength conversion layer. However, the requirements for thelight-recycling envelope needed to enhance the brightness of the lightsource in illumination system 100 are similar if not identical to therequirements for the light-recycling envelope needed for illuminationsystems that do incorporate a wavelength conversion layer.

The embodiments of this invention all utilize a wavelength conversionlayer located inside the light-recycling envelope. The wavelengthconversion layer converts a portion of the light of a first wavelengthrange emitted by the light source into light of a second wavelengthrange, different from the light of a first wavelength range. There areeffectively two light emitters in the embodiments of this invention.There is a primary light source, one or more LEDs or semiconductorlasers, which emits light of a first wavelength range. There is also asecondary light source, the wavelength conversion layer, which emitslight of a second wavelength range. However, the brightness of the lightof a second wavelength range emitted by the wavelength conversion layerdepends on the light of a first wavelength range emitted by the primarylight source and therefore the wavelength conversion layer is not anindependent light emitter.

Determining if an illumination system utilizing a wavelength conversionlayer and light recycling has enhanced output brightness when comparedto an illumination system that does not recycle light is not as simpleas in the example of illumination system 100, which has no wavelengthconversion layer. As stated previously, recycled light refers to lightthat is emitted by the light source or the wavelength conversion layerand is subsequently reflected back to either the light source or thewavelength conversion layer.

First, one must decide whether to measure brightness in radiance unitsor luminance units. This can become complex when the illumination systemincorporates light of multiple wavelengths, as in the embodiments ofthis invention where light of a first wavelength range and light of asecond wavelength range are both emitted by the illumination system.Luminance is a brightness measurement that is related to the human eyeresponse. Radiance is a brightness measurement that does not depend onthe response of the human eye. For example, a 450-nanometer light sourceand a 580-nm light source that have equal brightness when measured inradiance units have unequal brightness when measured in luminance units.In this example, the 580-nanometer light source has higher luminancethan the 450-nanometer light source due to the greater sensitivity ofthe human eye to 580-nanometer light than to 450-nanometer light.

Second, one must choose a reference illumination system such that thereference illumination system is similar to the light-recyclingillumination system under test with the exception that the referenceillumination system does not recycle light. More than one referenceillumination system can be chosen for the comparison.

The embodiments of this invention differ depending on the method chosenfor comparing an illumination system that recycles light to a similarreference illumination system that does not recycle light.

In the first embodiment of this invention, the reference illuminationsystem is the light source, which is at least one LED, and does notinclude any light reflected or emitted by the light-recycling envelopeor the wavelength conversion layer. The brightness of the light sourceis designated as the maximum intrinsic source radiance or the maximumintrinsic source luminance. The word “maximum” is included because theradiance or luminance of the light source may vary with angle if thelight source is not a perfect Lambertian emitter. If the radiance orluminance of the light source varies with angle, the maximum value ofthe radiance or luminance is chosen as the reference value.

The output radiance of light exiting the improved illumination system ofthe first embodiment is denoted as the combined exiting radiance, andincludes both light of a first wavelength range and light of a secondwavelength range. The output luminance of light exiting the improvedillumination system is denoted as the combined exiting luminance, andincludes both light of a first wavelength range and light of a secondwavelength range. Although the output brightness of the light-recyclingillumination system can be compared to the reference illumination systemeither in radiance units or luminance units, preferably the brightnessis compared in radiance units to eliminate the effects of the human eyeresponse.

To determine if brightness enhancement can take place for the firstembodiment, one must also compare the total light output aperture areaA_(O) of the light-recycling illumination system under test to areference area of the reference illumination system. The reference areafor the first embodiment is the total light-emitting area of the lightsource, denoted as area A_(S). Examples of the first embodiment of thisinvention are illustrated in FIGS. 5–10.

In the second embodiment of this invention, the reference illuminationsystem is both the light source, which is an LED, and the wavelengthconversion layer operating in combination. The reference illuminationsystem does not include the light-recycling envelope or any lightreflected by the light-recycling envelope. The brightness of thereference illumination system is designated as the maximum combinedintrinsic radiance or the maximum combined intrinsic luminance of thelight source and the wavelength conversion layer operating incombination. The word “maximum” is included because the radiance orluminance of the light source and wavelength conversion layer operatingin combination may vary with angle if the light emission is not aperfectly Lambertian. If the radiance or luminance varies with angle,the maximum value of the radiance or luminance is chosen as thereference value.

The output radiance of light exiting the improved illumination system ofthe second embodiment is denoted as the combined exiting radiance, andincludes both light of a first wavelength range and light of a secondwavelength range. The output luminance of light exiting the improvedillumination system is denoted as the combined exiting luminance, andincludes both light of a first wavelength range and light of a secondwavelength range. Since the reference illumination system includes bothlight of a first wavelength range and light of a second wavelengthrange, the output brightness of the light-recycling illumination systemcan be compared to the reference illumination system either in radianceunits or luminance units.

To determine if brightness enhancement can take place for the secondembodiment, one must also compare the total light output aperture areaA_(O) of the light-recycling illumination system under test to areference area of the reference illumination system. Ideally thereference area should be the total emitting area for the combination ofthe light source and the wavelength conversion layer. However, theemitting area for the combination of the light source and the wavelengthconversion area may be hard to determine in some cases since thewavelength conversion layer can have a multitude of shapes and can havecomplicated surface features. For example, the wavelength conversionlayer can be a coating on the light-recycling envelope, can be a coatingon the light source, can be a coating on both the light-recyclingenvelope and the light source or the wavelength conversion layer canpartially fill or completely fill the light-recycling envelope. In orderto eliminate the difficulty in determining the emitting area for thecombination of the light source and the wavelength conversion area, thereference area in the second embodiment is chosen instead to be themaximum cross-sectional area of the light-recycling envelope, denoted asarea A_(E). The maximum cross-sectional area A_(E) of thelight-recycling envelope is an easier quantity to determine and isusually approximately equivalent to the combined emitting area of thelight source and the wavelength conversion area. Examples of the secondembodiment are illustrated in FIGS. 11–19.

In the third embodiment of this invention, the reference illuminationsystem is both the light source, which is a semiconductor laser, and thewavelength conversion layer operating in combination. The referenceillumination system does not include the light-recycling envelope or anylight reflected by the light-recycling envelope. The referencebrightness includes only light of a second wavelength range and does notinclude light of a first wavelength range. The brightness of thereference illumination system is designated as the maximum combinedintrinsic radiance of light of a second wavelength range or the maximumcombined intrinsic luminance of light of a second wavelength range thatis emitted when the light source and the wavelength conversion layeroperate in combination. The word “maximum” is included because theradiance or luminance of the light source and the wavelength conversionlayer operating in combination may vary with angle if the combination isnot a perfect Lambertian emitter. If the radiance or luminance varieswith angle, the maximum value of the radiance or luminance is chosen asthe reference value. The light of a first wavelength range emitted bythe semiconductor laser was not included in the reference. Semiconductorlasers generally emit light of a first wavelength range in a narrowangular distribution and have high brightness. It is usually notnecessary to increase the brightness of the semiconductor laser using alight-recycling envelope. In addition, the output area of semiconductorlaser is small and, in many instances, will be less than the area A_(O)of the light output aperture of the illumination system. The importanceof the light-recycling envelope in the third embodiment of thisinvention is to increase the brightness of the light of a secondwavelength range emitted by the wavelength conversion layer.

In the third embodiment of this invention, the brightness of the lightof a second wavelength range exiting an improved light-recyclingillumination system and the brightness of the light of a secondwavelength range exiting a reference illumination system that does notutilize light recycling can be compared either in radiance units orluminance units. The output radiance of light exiting the improvedillumination system of the third embodiment is denoted as the exitingradiance of light of a second wavelength range, and does not includelight of a first wavelength range. The output luminance of light exitingthe improved illumination system is denoted as the exiting luminance oflight of a second wavelength range, and does not include light of afirst wavelength range.

In order to determine if brightness enhancement can occur for the thirdembodiment, one must compare the total light output aperture area A_(O)of the light-recycling illumination system under test to a referencearea of the reference illumination system. As for the second embodiment,the reference area for the third embodiment is chosen to be the maximumcross-sectional area of the light-recycling envelope, denoted as areaA_(E). Examples of the third embodiment are illustrated in FIGS. 20–22.

Example embodiments of this invention that are related to the firstembodiment will now be described in detail using the illustrations inFIGS. 5–10.

One embodiment of the present invention is illumination system 200 shownin FIGS. 5A–5G. Illumination system 200 is similar to illuminationsystem 100 in FIGS. 4A–4D except that illumination system 200 contains awavelength conversion layer 214. Illumination system 200 is comprised ofa light source, which is LED 206, a wavelength conversion layer 214, alight-recycling envelope 202 and a light output aperture 204.

A top external view of illumination system 200 is illustrated in FIG.5A, showing the outer edge of the light-recycling envelope 202 and thelight output aperture 204 as solid lines. FIG. 5B is a cross-sectionalview along the I—I plane indicated in FIG. 5A. FIG. 5C is across-sectional view along the II—II plane indicated in FIG. 5A. TheII—II plane passes through the light output aperture 204 and LED 206.FIGS. 5D–5G show the paths of some representative light rays emittedfrom LED 206.

For illumination system 200, the cubical three-dimensional shape of thesurface of the light-recycling envelope 202, the square cross-sectionalshape of the light-recycling envelope 202 and the square shape of thelight output aperture 204 are illustrative examples used for ease ofunderstanding of the invention. It should also be noted that the drawingis merely a representation of the structure; the actual and relativedimensions may be different.

As noted previously, the light-recycling envelope 202 may be anythree-dimensional surface that encloses an interior volume. Similarly,the cross-section of the light-recycling envelope 202 shown in FIG. 5Cmay have any shape, either regular or irregular, depending on the shapeof the three-dimensional surface of the light-recycling envelope 202.

The square cross-sectional shape of illumination system 200 shown inFIG. 5C has a first side containing the light output aperture 204, asecond side, a third side and a fourth side. The first side is oppositeand parallel to the third side. The second side is opposite and parallelto the fourth side. The first side and third side are perpendicular tothe second side and fourth side. The four sides of the illuminationsystem shown in cross-section in FIG. 5C plus the two remaining sides ofthe six-sided cube (not shown in the cross-sectional view) form theinterior of the light-recycling envelope.

The inside surfaces of the light-recycling envelope 202, except for thearea occupied by the LED 206 and the area occupied by the light outputaperture 204, are light reflecting surfaces. The light-recyclingenvelope reflects both light of a first wavelength range and light of asecond wavelength range. In order to achieve high light reflectivity,the light-recycling envelope 202 may be fabricated from a bulk materialthat is intrinsically reflective or the inside surfaces of thelight-recycling envelope 202 may be covered with a reflective coating.The bulk material or the reflective coating may be a specular reflector,a diffuse reflector or a diffuse reflector that is backed with aspecular reflecting layer. Examples of reflective materials and coatingswere described previously. Preferably the reflectivity R_(E) of theinside surfaces of the light-recycling envelope 202 that are notoccupied by the LED 206 and the light output aperture 204 is at least50%. More preferably, the reflectivity R_(E) is at least 70%. Mostpreferably, the reflectivity R_(E) is at least 90%. Ideally, thereflectivity R_(E) should be as close to 100% as possible in order tomaximize the output efficiency of the illumination system.

As illustrated in FIGS. 5A–5G, the wavelength conversion layer 214 isformed as a coating on the inner surfaces of the sides of thelight-recycling envelope 202. The wavelength conversion layer in FIGS.5A–5G is shown for illustrative purposes to cover the entire surface ofthe light-recycling envelope except for the LED 206 and the light outputaperture 204. However, it is not necessary that the wavelengthconversion layer cover the entire surface of the light-recyclingenvelope. It is also within the scope of this invention that thewavelength conversion layer may cover only a part of the light-recyclingenvelope.

The wavelength conversion layer 214 converts a portion of the light of afirst wavelength range emitted by the light source into light of asecond wavelength range, different from the light of a first wavelengthrange. The light of the second wavelength range has longer wavelengthsand lower energies than the light of the first wavelength range,resulting in an energy loss for wavelength conversion.

The total energy efficiency ρ_(T) of wavelength conversion of light of afirst wavelength range into light of a second wavelength range is givenby the equationη_(T)=η_(QE)η_(S),  [Equation 6]where η_(QE) is the quantum efficiency for converting a photon of lightof a first wavelength range into a photon of light of a secondwavelength range and where η_(S) is the relative energy loss due to theStokes shift. The Stokes shift is a shift to longer wavelengths andlower energies that occurs when light of a first wavelength range isconverted into light of a second wavelength range. Preferably forefficient wavelength conversion, η_(QE) should be greater than 0.80, andmore preferably, η_(QE) should be greater than 0.90. The quantity η_(S)depends on the magnitude of the wavelength shift. For example, if thelight of a first wavelength range has a wavelength of 450 nanometers andthe light of a second wavelength range has a wavelength of 580nanometers, then η_(S) is 0.78 since a 580-nanometer photon has 78% ofthe energy of a 450-nanometer photon. A small wavelength shift resultsin a small energy loss due to the Stokes shift, whereas a largewavelength shift results in a large energy loss.

The wavelength conversion layer 214 is comprised of a powdered phosphormaterial, a quantum dot material, a luminescent dopant material or aplurality of such materials. In addition, the wavelength conversionlayer may further comprise a transparent host material into which thephosphor material, the quantum dot material or the luminescent dopantmaterial is dispersed. Examples of powdered phosphor materials, quantumdot materials, luminescent dopant materials and transparent hostmaterials were listed previously. For illustrative purposes, thewavelength conversion layer 214 in FIGS. 5A–5G is shown to be comprisedof particles dispersed in a transparent coating layer.

Depending on the materials that comprise the wavelength conversionlayer, the wavelength conversion layer may also partially reflect thelight of a first wavelength range and the light of a second wavelengthrange incident upon the wavelength conversion layer. In such cases,light may reflect from the sides of the illumination system byreflecting from either the light-recycling envelope 202 or thewavelength conversion layer 214. The wavelength conversion layer ischosen not to interfere with the light-reflecting properties of thelight-recycling envelope and the light-recycling envelope is chosen notto interfere with the wavelength conversion properties of the wavelengthconversion layer.

The light source for illumination system 200 is LED 206, which islocated on the fourth side of the light-recycling envelope. LED 206 maybe an inorganic light-emitting diode or an OLED. Preferably, LED 206 isan inorganic light-emitting diode. Examples of inorganic light-emittingdiodes have been listed previously.

LED 206 has an emitting layer 208 and a reflecting layer 210. The totallight-emitting area of the light source is area A_(S), which in thisexample is the light-emitting area of emitting layer 208. The emittinglayer 208 emits light of a first wavelength range. Light may be emittedfrom emitting layer 208 through one or more surfaces of emitting layer208 that are not in contact with reflecting layer 210. For example,light may be emitted through surface 212.

The light of a first wavelength range emitted by the emitting layer 208is preferably greater than 200 nanometers in wavelength and less than3000 nanometers in wavelength. More preferably, the light of a firstwavelength range is greater than 200 nanometers in wavelength and lessthan 450 nanometers in wavelength.

The light of a first wavelength range emitted by LED 206 has a maximumintrinsic source radiance and a maximum intrinsic source luminance thatdepend on the LED design and the driving electrical power applied to theLED. The maximum intrinsic source radiance and the maximum intrinsicsource luminance are measured for the light source alone with nolight-recycling envelope and no wavelength conversion layer present.

The reflecting layer 210 is adjacent to and interior to the fourth sidewhile the emitting layer extends into the interior of thelight-recycling envelope. The reflecting layer 210 reflects both lightof a first wavelength range and light of a second wavelength range. Thereflecting layer 210 may be a specular reflector or a diffuse reflector.In a typical inorganic light-emitting diode, the reflecting layer isusually a specular reflector. The light reflectivity of reflecting layer210 of LED 206 is R_(S). If the reflectivity varies across the area ofthe reflecting layer, the reflectivity R_(S) is defined as the averagereflectivity of the reflecting layer. The reflectivity R_(S) ofreflecting layer 210 is preferably at least 50%. More preferably, thereflectivity R_(S) is at least 70%. Most preferably, the reflectivityR_(S) is at least 90%. Ideally, the reflectivity R_(S) should be asclose to 100% as possible in order to maximize the efficiency and thelight output brightness of the illumination system.

In order to explain the operation of illumination system 200, examplelight rays emitted from LED 206 are illustrated in FIGS. 5D, 5E, 5F and5G.

In FIG. 5D, a first light ray 216 of a first wavelength range is emittedfrom surface 212 of emitting layer 208 on the fourth side of thelight-recycling envelope 202 and passes through the interior of thelight-recycling envelope to exit the light output aperture 204 on thefirst side of the light-recycling envelope without reflecting off thelight-recycling envelope or interacting with the wavelength conversionlayer 214.

A second light ray 218 of a first wavelength range is emitted fromsurface 212 of emitting layer 208 and passes through the interior of thelight-recycling envelope 202 to the surface of the wavelength conversionlayer 214 on the third side of the light-recycling envelope. Light ray218 passes through the wavelength conversion layer 214, reflects off thelight-recycling envelope 202 and passes through the wavelengthconversion layer 214 a second time. In both passes through thewavelength conversion layer 214, the light ray 218 is not converted tolight of a second wavelength range. Finally, light ray 218 passesthrough the interior of the light-recycling envelope to exit through thelight output aperture 204 on the first side of the light-recyclingenvelope as light of a first wavelength range.

A third light ray 220 of a first wavelength range is emitted fromsurface 212 of emitting layer 208 and passes through the interior of thelight-recycling envelope to the surface of the wavelength conversionlayer 214 on the third side of the light-recycling envelope. Light ray220 is converted by the wavelength conversion layer 214 to light ray 222of a second wavelength range, different than the light of a firstwavelength range. The emission of light ray 222 can occur in anydirection from the wavelength conversion layer. In this example, lightray 222 passes through the interior of the light-recycling envelope toexit through the light output aperture 204. As an alternative optionthat is not illustrated, if light ray 222 is emitted towards thelight-recycling envelope 202 on the third side of the light-recyclingenvelope, light ray 222 will be reflected by the light-recyclingenvelope 202, pass through the wavelength conversion layer 214 andthrough the interior of the light-recycling envelope to exit through thelight output aperture 204. Light of a second wavelength range emitted bythe wavelength conversion layer will not be converted again during oneor more additional passes through the wavelength conversion layer.

Each time a light ray of a first wavelength range passes through thewavelength conversion layer, the wavelength conversion layer converts aportion of the light of a first wavelength range into light of a secondwavelength range, different from the light of a first wavelength range.Each time a light ray of a second wavelength range passes through thewavelength conversion layer, the light of a second wavelength range willbe unaffected. The light of a second wavelength range will not alter itswavelength nor will additional wavelengths be formed.

The probability that a light ray of the first wavelength range will beconverted to a light ray of a second wavelength range upon passagethrough the wavelength conversion layer depends on the type of materialin the wavelength conversion layer, depends on the density of thepowdered phosphor material, the quantum dot material or the luminescentdopant material within the layer and depends on the thickness of thewavelength conversion layer. The probability of wavelength conversioncan be increased either by increasing the density of the powderedphosphor material, the quantum dot material or the luminescent dopantmaterial within the wavelength conversion layer or by increasing thethickness of the layer. However, for some materials such as the quantumdot materials, increasing the density of the material lowers theconversion efficiency of the material due to particle-particleinteractions. In such cases, a low quantum dot material density may bedesired. Then, in order to achieve a high overall conversion efficiencyfor the illumination system, either a thicker wavelength conversionlayer must be used or increased light recycling is needed so that lightof a first wavelength range can pass through the wavelength conversionlayer many times.

In FIG. 5D, light ray 218 of a first wavelength range is not convertedto light of a second wavelength range. Light ray 220 of a firstwavelength range is converted to light ray 222 of a second wavelengthrange. Overall, the wavelength conversion layer converts a portion ofthe light of a first wavelength range into light of a second wavelengthrange, different than the light of a first wavelength range.

In FIG. 5D, a fourth light ray 223 of a first wavelength range isemitted from surface 212 of emitting layer 208 on the fourth side of thelight-recycling envelope. Light ray 223 passes through the interior ofthe light-recycling envelope to the wavelength conversion layer 214 onthe second side. Light ray passes through the wavelength conversionlayer and is absorbed by the light-recycling envelope. In general, thelight-recycling envelope and the reflecting layer 210 are not perfectreflectors and each has a reflectivity less than 100%. Some of the lightof a first wavelength range, such as light ray 223, and some of thelight of a second wavelength range will be absorbed. Due to theabsorption losses, only a fraction of the light of a first wavelengthrange that is inside the light-recycling envelope will exit thelight-recycling envelope through the light output aperture 204.Likewise, only a fraction of the light of a second wavelength range thatis inside the light-recycling envelope will exit the light-recyclingenvelope through the light output aperture 204.

In FIG. 5E, a fifth light ray 224 of a first wavelength range is emittedfrom surface 212 of emitting layer 208 on the fourth side of thelight-recycling envelope and passes through the interior of thelight-recycling envelope to wavelength conversion layer 214 on the thirdside of the light-recycling envelope. Light ray 224 passes throughwavelength conversion layer 214 without converting, reflects offlight-recycling envelope 202, passes through wavelength conversion layer214 a second time without converting and passes through the interior ofthe light-recycling envelope to wavelength conversion layer 214 on thesecond side of the light-recycling envelope. Light ray 224 then passesthrough wavelength conversion 214 a third time without converting,reflects off light-recycling envelope 202, passes through wavelengthconversion layer 214 a fourth time without converting, passes throughthe interior of the light-recycling envelope and exits thelight-recycling envelope through the light output aperture 204 on thefourth side of the light-recycling envelope.

A sixth light ray 226 of a first wavelength range is emitted fromsurface 212 of emitting layer 208 on the fourth side of thelight-recycling envelope and passes through the interior of thelight-recycling envelope to wavelength conversion layer 214 on the thirdside of the light-recycling envelope. Light ray 226 of a firstwavelength range is converted to light ray 228 of a second wavelengthrange by the wavelength conversion layer. In general, light ray 228 maybe emitted in any direction by the wavelength conversion layer. In thisillustration, light ray 228 is emitted toward the interior of thelight-recycling envelope, passes through the interior of thelight-recycling envelope to wavelength conversion layer 214 on thesecond side of the light-recycling envelope. Light ray 228 passesthrough wavelength conversion layer 214, reflects off light-recyclingenvelope 202 on the second side of the light-recycling envelope andagain passes through wavelength conversion layer 214. Since light ray228 has already been converted, addition passes through wavelengthconversion layer 214 will not result in further conversion. Light ray228 then passes through the interior of the light-recycling envelope andexits through light output aperture 204 on the first side of thelight-recycling envelope.

Light rays 224, 226 and 228 in FIG. 5E illustrate rays that reflectmultiple times inside the light-recycling envelope. In general, lightrays may reflect many times inside the light-reflecting envelope beforeeither exiting the illumination system through light output aperture 204or being absorbed by the light-recycling envelope, the LED or thewavelength conversion material. A multitude of light pathways ispossible. Light of a first wavelength range may be converted to light ofa second wavelength range on the first pass through the wavelengthconversion layer, may be converted only after many passes through thewavelength conversion layer, or may exit the illumination system withoutbeing converted. Light that has already been converted to light of asecond wavelength range will not be converted again. The light-recyclingenvelope directs a part of the light of a first wavelength through thewavelength conversion layer multiple times and increases the likelihoodthat the light of a first wavelength range will be converted to light ofa second wavelength range.

The light exiting the light output aperture 204 in FIGS. 5D and 5E is amixture of light of a first wavelength range and light of a secondwavelength range. If both wavelength ranges are in the visiblewavelength region of the optical spectrum, the mixture of light exitingthe light output aperture will have a composite color. By changing thesize of the light-recycling envelope, changing the thickness of thewavelength conversion layer, changing the characteristics of the lightsource or changing the size of the light output aperture, the ratio ofthe flux of light of a first wavelength range to the flux of light of asecond wavelength range can be varied. By varying this ratio, the colorof the light exiting the light output aperture can be varied.

If the composite color exiting the light output aperture 204 is whitelight, the quality of the white light can be changed by varying theratio of light of a first wavelength range to light of a secondwavelength range exiting from the light output aperture. The quality ofthe white light can be described by a color-rendering index. Acolor-rendering index of 100 indicates that the white light shining on acolored surface will reproduce the surface colors as seen by the humaneye in an identical manner to light from the sun shining on the surface.A color-rendering index less than 100 indicates that the white lightshining on a colored surface will give an apparent surface color thatappears different to the human eye than the color seen by the human eyeusing sunlight. By changing the size of the light-recycling envelope,changing the thickness of the wavelength conversion layer, changing thecharacteristics of the light source or changing the size of the lightoutput aperture, the ratio of the flux of light, of a first wavelengthrange to the flux of light of a second wavelength range can be varied.By varying this ratio, the color-rendering index of the light exitingthe light output aperture can be varied. The light-recycling envelope ofthis invention can recycle light of a first wavelength range backthrough the wavelength conversion layer one or more times to improve theoverall efficiency of converting light of a first wavelength range intolight of a second wavelength range. In addition, by utilizing such lightrecycling and by varying the physical dimensions and characteristics ofthe light-recycling envelope, the color-rendering index of the lightexiting the light output aperture can be improved to achieve the maximumvalue allowed for the combination of the two wavelength ranges.

Light rays in FIGS. 5F and 5G illustrate light recycling that canincrease the effective brightness of the light source and enhance thebrightness of the light exiting the light output aperture 204.

A seventh light ray 230 of a first wavelength range is emitted fromsurface 212 of emitting layer 208 on the fourth side of illuminationsystem 200 in a first time period. Light ray 230 passes through theinterior of the light-recycling envelope 202 to wavelength conversionlayer 214 on the second side. Light ray 230 passes through wavelengthconversion layer 214 a first time, is reflected by the light-recyclingenvelope, passes through the wavelength conversion layer 214 a secondtime and then passes through the interior of the light-recyclingenvelope to the wavelength conversion layer 214 on the third side. Lightray 230 passes through the wavelength conversion layer 214 a third time,is reflected by the light-recycling envelope on the third side, passesthrough the wavelength conversion layer a fourth time and then passesthrough the interior of the light-recycling envelope to the surface 212.Light ray 230 is transmitted through surface 212 and through theemitting layer 208 a first time, is reflected by the reflecting layer210 and is transmitted through the emitting layer 208 and the surface212 a second time and during a second time period. When light ray 230passes through emitting layer 208, light ray 230 does not effect thelight emission of emitting layer 208. Light ray 230 then passes throughthe interior of the light-recycling envelope and exits the illuminationsystem through the light output aperture 204 as light of a firstwavelength range.

When the seventh light ray 230 reflects off reflecting layer 210 of LED206 and is transmitted through emitting layer 208 and surface 212 toenter the light-recycling envelope during a second time period, thereflected light ray 230 adds to the light rays concurrently beingemitted by emitting layer 208 of LED 206 during the second time period.The reflected light ray increases the effective source radiance and theeffective source luminance of LED 206 so that the effective sourceradiance and effective source luminance are then higher than therespective maximum intrinsic source radiance and the maximum intrinsicsource luminance of LED 206 measured in the absence of light recycling.

In FIG. 5G, an eighth light ray 234 of a first wavelength range isemitted from surface 212 of emitting layer 208 of LED 206 in a firsttime period. Light ray 234 passes through the interior of thelight-recycling envelope 202 to the wavelength conversion layer 214 onthe second side. Wavelength conversion layer 214 converts light ray 234of a first wavelength range into light ray 236 of a second wavelengthrange, different than the light of a first wavelength range. Light ray236 may be emitted in any direction from wavelength conversion layer214. In this example, light ray 236 is emitted toward thelight-recycling envelope on the second side, passes through thewavelength conversion layer a first time, is reflected by thelight-recycling envelope on the second side, passes through thewavelength conversion layer a second time, passes through the interiorof the light-recycling envelope to the wavelength conversion layer onthe third side. The wavelength conversion layer 214 may be a partialreflector to light of a first wavelength range and to light of a secondwavelength range. Light ray 236 may either be reflected by wavelengthconversion layer 214 or pass through the wavelength conversion layer. Inthis example, light ray 236 is reflected by the wavelength conversionlayer on the third side and passes through the interior of thelight-recycling envelope to the surface 212. Light ray 236 istransmitted through surface 212 and emitting layer 208 a first time, isreflected by reflecting layer 210, is transmitted through emitting layer208 and surface 212 a second time and during a second time period. Whenlight ray 236 passes through emitting layer 208, light ray 236 does noteffect the light emission of emitting layer 208. Light ray 236 thenpasses through the interior of the light-recycling envelope and exitsthe illumination system through the light output aperture 204 as lightof a second wavelength range.

When the light ray 236 reflects off reflecting layer 210 of LED 206 andis transmitted through emitting layer 208 and surface 212 to enter thelight-recycling envelope during a second time period, the reflectedlight ray 236 adds to the light rays concurrently being emitted byemitting layer 208 of LED 206 during the second time period. Thereflected light ray increases the effective source radiance and theeffective source luminance of LED 206 so that the effective sourceradiance and effective source luminance are then higher than therespective maximum intrinsic source radiance and the maximum intrinsicsource luminance of LED 206 measured in the absence of light recycling.

Light rays 216, 218, 220, 222, 224, 226 and 228 are not recycled back tothe light source. Light rays 230 and 236 are recycled back to the lightsource. Only part of the light of first wavelength range and part of thelight of a second wavelength range are recycled back to the lightsource.

Illumination system 200 has one light output aperture 204. The totallight output aperture area is area A_(O). It is also within the scope ofthis invention that illumination system 200 can have more than one lightoutput aperture. If there is more than one light output aperture, thetotal light output aperture area is also defined as area A_(O).

The output radiance of light exiting the light output aperture 204 isdenoted as the combined exiting radiance, and includes both light of afirst wavelength range and light of a second wavelength range. Theoutput luminance of light exiting the light output aperture 204 isdenoted as the combined exiting luminance, and includes both light of afirst wavelength range and light of a second wavelength range.

To determine if illumination system 200 has enhanced output brightness,one must compare the combined output radiance or the combined outputluminance of illumination system 200 to the brightness of a referenceillumination system. As stated above for the first embodiment of thisinvention, the reference brightness is the maximum intrinsic sourceradiance or maximum intrinsic source luminance of the light source, LED206, measured alone with no wavelength conversion layer and nolight-recycling envelope. The reference brightness can be determined bymeasuring a reference LED that is substantially identical to LED 206operating at an electrical power that is substantially identical to theelectrical power used to power LED 206.

For the comparative brightness measurements, one can measure eitherradiance or luminance. In order to remove the effects of the response ofthe human eye to different wavelengths of light, preferably thebrightness measurement is done in radiance units.

As in illumination system 100, the brightness (measured in radianceunits) of the light exiting the light output aperture 204 inillumination system 200 cannot be greater than the effective brightnessof the light source. In illumination system 100, a part of the light ofa first wavelength can be recycled back to the light source to increasethe effective brightness of the light source. In illumination system200, by comparison, both a part of the light of a first wavelength rangeemitted by LED 206 and a part of the light of a second wavelength rangeemitted by the wavelength conversion layer 214 can be recycled back toLED 206 to increase the effective radiance of LED 206. By increasing theeffective radiance of LED 206 through light recycling, the combinedexiting radiance of the light exiting the light output aperture 204 canalso be increased to values greater than the maximum intrinsic sourceradiance of LED 206 in the absence of light recycling.

As in illumination system 100, the maximum reflectivity of the insidesurfaces of illumination system 200 and the resulting combined exitingradiance emitted from the light output aperture 204 is achieved bypreferably having substantially all of the interior surfaces ofillumination system 200 be reflective except for the total area A_(O) ofall the apertures in the light-recycling envelope. Illumination system200, illustrated in FIGS. 5A–5G, has just one light output aperture 204having area A_(O). The total inside area of the light-recycling envelopeis A_(T), which includes the area A_(O) and the total light-emittingarea of the light source. The LED light source has a reflecting layerhaving reflectivity R_(S). The total light-emitting area of the lightsource is area A_(S). In the example of FIGS. 5A–5G, area A_(S) is thelight-emitting area of LED 206, but for other examples having more thanone LED, A_(S) is the total light-emitting area of all the LEDs withinthe light-recycling envelope. The remaining inside area of thelight-recycling envelope that is not covered by the total light-emittingarea A_(S) of the LEDs and the area A_(O) of the output aperture orapertures is denoted as remaining area A_(R). It is preferable thatsubstantially all of remaining area A_(R) should have a reflectivesurface of reflectivity R_(E) to maximize the radiance exiting from thelight output aperture or apertures. As noted previously, thereflectivity R_(E) is preferably at least 50%. More preferably, thereflectivity R_(E) is at least 70%. Most preferably, the reflectivityR_(E) is at least 90%. Also noted previously, the wavelength conversionlayer 214 that coats at least a part of the area A_(R) of thelight-recycling envelope may also reflect light. Light of a firstwavelength range and light of a second wavelength range may be reflectedby either the wavelength conversion layer or the light-recyclingenvelope. However, the reflectivity of the wavelength conversion layeris generally less than the reflectivity R_(E) of the light-recyclingenvelope. As long as the wavelength conversion layer has little or noabsorption, the total reflectivity of the light-recycling envelopecoated with the wavelength conversion layer will be substantially thesame as the reflectivity R_(E) of the light-recycling envelope without acoating of the wavelength conversion material.

The illumination system 200 can achieve a combined exiting radiance thatis greater than the maximum intrinsic source radiance only if the totallight output aperture area A_(O) of the light output aperture 204 isless than the total light-emitting area A_(S) of the light source. Thiscan be demonstrated in the same manner as for illumination system 100 byhypothesizing an ideal illumination system where R_(S) and R_(E) eachequal 100% and no light is lost or absorbed inside the illuminationsystem. One must also assume that the ideal light source emits light ina Lambertian distribution.

If the light output area A_(O) is smaller than the total light-emittingarea A_(S) and no light is lost or absorbed inside the idealillumination system, the light exiting the light output area will, inmany cases, have the same Lambertian distribution but will have abrightness greater than the intrinsic source brightness due to thereduced area of the light output aperture. The output brightness exitingthe light output aperture will be greater by a factor of A_(S)/A_(O). Inorder to achieve an output brightness exiting the light output aperture204 that is greater than the maximum intrinsic source brightness, it istherefore a requirement that the output area A_(O) be less than thetotal light-emitting area A_(S).

However, again as in illumination system 100, the area requirement thatA_(O) must be less than A_(S) is not the only requirement needed inorder to achieve brightness enhancement in illumination system 200. In atypical illumination system, the reflectivity R_(S) and the reflectivityR_(E) will be less than 100%, which will lower the brightnessenhancement. Light that does not exit the light output aperture 204 onthe first attempt may be absorbed by the light source or thelight-recycling envelope or the wavelength conversion layer as it isreflected one or more times inside the light-recycling envelope. Theselosses will reduce the output brightness. Therefore, in order to achievebrightness enhancement in a typical illumination system, R_(S) and R_(E)must be relatively high even if they are not 100%. The preferred valuesfor R_(S) and R_(E) were listed previously.

Furthermore, in a typical illumination system, the light source maysometimes not emit light in a wide Lambertian (−90 degrees to +90degrees) angular distribution but in a narrower angular distribution.When a light source emits light in a narrower angular distribution andwhen the emitted light then undergoes multiple reflections inside theillumination system, the light exiting the light output aperture willhave a wider angular distribution than the initial angular distribution.The output distribution will approach a Lambertian distribution.Expanding the initial narrow angular distribution to a wider outputdistribution inside the illumination system will also reduce thebrightness of the light exiting the light output aperture. Therefore, inorder to achieve brightness enhancement in a typical illuminationsystem, the angular distribution of the light emitted by the lightsource preferably should be as close to a Lambertian distribution aspossible.

The maximum theoretical radiance enhancement of illumination system 200is given by the ratio of the areas A_(S)/A_(O) as shown above. Forexample, if As equals 20 mm² and A_(O) equals 1 mm², then the maximumtheoretical radiance enhancement is A_(S)/A_(O) or 20. The maximum valueis achieved only if the LED is a Lambertian emitter and only if R_(S)and R_(E) each equal 100%. If the LED is not a perfect Lambertianemitter or if R_(S) and R_(E) are each less than 100%, as is normallythe case, radiance enhancement can still be achieved but the enhancementwill be less than the maximum theoretical value. In such cases, the areaA_(O) may need to be significantly less than A_(S) in order to achieve acombined exiting radiance that is greater than the maximum intrinsicsource radiance. Accordingly, the area A_(O) of the light outputaperture 204 is preferably less than or equal to 50% of the totallight-emitting area A_(S) of the light source. More preferably, the areaA_(O) is less than or equal to 30% of the total light-emitting areaA_(S) of the light source. Most preferably, the area A_(O) is less thanor equal to 10% of the total light-emitting area A_(S) of the lightsource. In addition, for some applications it is desirable that the areaA_(O) of the light output aperture 204 be small and comparable in sizeto the area of an arc lamp source. For those applications, preferablythe area A_(O) of the light output aperture 204 is less than 25 mm² inarea. More preferably, the area A_(O) of the light output aperture 204is less than 10 mm².

Any output radiance enhancement from illumination system 200 is a resultof light recycling and is independent of the wavelength sensitivity ofthe human eye. Using the same light-recycling techniques, it is alsopossible to get an output luminance enhancement from illumination system200. However, there are special situations using the first embodimentsuch that luminance enhancement may sometimes occur in the absence ofrecycling if the human eye is less sensitive to the light of a firstwavelength range emitted by the light source than to the light of asecond wavelength range emitted by the wavelength conversion layer uponwavelength conversion. Such a situation may occur, for example, if thelight of a first wavelength range is 430-nanometer light and light of asecond wavelength range is 580-nanometer light. The human eye is moresensitive to 580-nanometer light than 430-nanometer light. In such acase, when the wavelength conversion layer converts light of a firstwavelength range into light of a second wavelength range, the human eyemay see a luminance enhancement even in cases where there is no lightrecycling. One must be careful to determine which of the two effectscauses luminance enhancement for the first embodiment. The problem oftrying to separate the differing luminance enhancement effects isalleviated in later examples by considering the second embodiment ofthis invention illustrated by FIGS. 11–19. In the second embodiment, thereference illumination system is changed from being just the lightsource by itself to being the light source and the wavelength conversionlayer operating in combination. The reference illumination system thenincludes both wavelength ranges and any resulting luminance enhancementin the illumination system is due to improvements resulting from lightrecycling.

Another embodiment of this invention is illumination system 240illustrated in cross-section in FIG. 6. Illumination system 240 iscomprised of a light-recycling envelope 202, an LED 206, a wavelengthconversion layer 214 that coats the inside surfaces of thelight-recycling envelope and a partially reflecting optical element 242.Illumination system 240 is identical to illumination system 200 exceptfor the addition of the partially reflecting optical element 242.Partially reflecting optical element 242 is preferably either areflective polarizer or a dichroic mirror.

A reflective polarizer is a polarizer that reflects light of a firstpolarization state and transmits light of a second polarization state.Polarization states can be states of linear polarization or states ofcircular polarization. Examples of suitable reflective polarizers areVikuiti™ Dual Brightness Enhancement Film (DBEF) made by 3M Corporationand polarizers made by NanoOpto Corporation and Moxtek Incorporated thatutilize subwavelength optical elements.

When the partially transparent optical element 242 is a reflectivepolarizer, the reflective polarizer is placed adjacent to the lightoutput aperture 204 and placed in the optical path of light exiting fromthe light output aperture 204. The adjacent position of the reflectivepolarizer can be either just outside the light-recycling envelope orjust inside the light-recycling envelope. The reflective polarizerreflects both light of a first wavelength range and light of a secondwavelength range that have a first polarization state. Also, thereflective polarizer transmits both light of a first wavelength rangeand light of a second wavelength range that have a second polarizationstate. The light of a first polarization state, either light of a firstwavelength range or light of a second wavelength range, is recycled backinto the light-recycling envelope. The light of a first polarizationstate recycled back into the light-recycling envelope will, aftermultiple reflections inside the light-recycling envelope, be convertedinto a mixture of light of a first polarization state and light of asecond polarization state. The converted light of a second polarizationstate will then be able to pass through the reflecting polarizer. Ifonly the second polarization state is desired for the output ofillumination system 240, recycling the first polarization state backinto the light-reflecting envelope to be converted into light of asecond polarization state will improve the overall efficiency and outputbrightness of illumination system 240.

Some illumination system applications require polarized light. Forexample, illumination systems utilized for flat-panel display orprojection display applications that incorporate liquid crystal display(LCD) panels or liquid-crystal-on-silicon (LCOS) display panels requireillumination systems that emit polarized light.

A dichroic mirror is, for example, a mirror that can reflect light of afirst wavelength range and transmit light of a second wavelength range.Dichroic mirrors may be utilized if light of a first wavelength rangeemitted by LED 206 is not desired in the light output from thelight-recycling envelope. Dichroic mirrors are commonly constructed byalternately depositing layers of two transparent dielectrics havingdifferent indexes of refraction onto a transparent substrate. Examplesof materials used for dielectric layers include silicon dioxide,titanium dioxide or magnesium fluoride.

When the partially transparent optical element 242 is a dichroic mirror,the dichroic mirror is placed adjacent to the light output aperture 204and placed in the optical path of light exiting from the light outputaperture 204. The adjacent position of the dichroic mirror can be eitherjust outside the light-recycling envelope or just inside thelight-recycling envelope. In FIG. 6, the partially reflecting opticalelement is a dichroic mirror and is positioned just outside the lightoutput aperture 204.

Light rays 244, 246 and 248 in FIG. 6 illustrate the function of thedichroic mirror. Light ray 244 of a first wavelength range is emittedfrom surface 212 of emitting layer 208 on the fourth side of theillumination system 240, passes through the interior of thelight-recycling envelope 202 and passes through the light outputaperture 204 a first time to reach the partially reflecting opticalelement 242, which in this example is a dichroic mirror. Light ray 244of a first wavelength range reflects off the dichroic mirror, passesthrough the light output aperture 204 a second time and is recycled backinto the interior of the light-recycling envelope 202.

Light ray 246 of a first wavelength range is emitted from surface 212 ofemitting layer 208 on the fourth side of the illumination system 240,passes through the interior of the light-recycling envelope 202 to thewavelength conversion layer 214 on the third side. The wavelengthconversion layer converts light ray 246 of a first wavelength range intolight ray 248 of a second wavelength range. Light ray 248 may be emittedin any direction. In this example, light ray 248 is emitted from thewavelength conversion layer on the third side, passes through theinterior of the light-recycling envelope 202, passes through the lightoutput aperture 204 on the first side and passes through the partiallyreflecting optical element 242, which is the dichroic mirror.

Overall, the dichroic mirror transmits light of a second wavelengthrange and reflects light of a first wavelength range back into thelight-recycling envelope. The wavelength conversion layer can convert aportion of the light of a first wavelength range that is recycled backinto the light-recycling envelope into light of a second wavelengthrange. The converted light of a second wavelength range can then passthrough the dichroic mirror. If only light of a second wavelength rangeis desired for the output of illumination system 240, recycling thelight of a first wavelength range back into the light-reflectingenvelope to be converted into light of a second wavelength range willimprove the overall efficiency and output brightness of illuminationsystem 240.

Illumination system 260 in FIG. 7 is identical to illumination system200 except that illumination system 260 further comprises alight-collimating element 262. Light-collimating element 262 can be anyoptical element that at least partially collimates the light exitingfrom the light output aperture 204. For example, the light-collimatingelement can be a convex lens, a tapered light guide, or a compoundparabolic reflector.

In FIG. 7, light-collimating element 262 is a compound parabolicreflector for illustrative purposes. The compound parabolic reflectormay be constructed from a solid transparent material. If the compoundparabolic reflector is constructed from such a solid transparentmaterial, light can pass through the material and reflect from the sidesof the compound parabolic reflector by total internal reflection.Alternatively, the compound parabolic reflector may be a hollowstructure. The sides of the compound parabolic reflector must then becovered with a reflective coating in order to reflect light.Light-collimating element 262 has an input surface 264, which isadjacent to the light output aperture 204, and an output surface 266.The input surface 264 accepts uncollimated light from the light outputaperture 204. The light-collimating element 262 partially collimates thepreviously uncollimated light and transmits the partially collimatedlight through the output surface 266. In order for the light-collimatingelement to partially collimate the light exiting the light outputaperture 204, the area of input surface 264 must be less than the areaof the output surface 266. Equation 5 gives the mathematicalrelationship between the input and output areas and the input and outputsolid angle distributions of the light.

Representative light rays 268, 270 and 272 are shown in FIG. 7 toillustrate the function of the light-collimating element 262 whenlight-collimating element 262 is a compound parabolic reflector. Lightray 268 of a first wavelength range is emitted from surface 212 ofemitting layer 208 on the first side, passes through the interior of thelight-recycling envelope 202, passes through the light output aperture204 on the first side and passes through input surface 264 of thecompound parabolic reflector as uncollimated light. Light ray 268 isreflected by the sides of the compound parabolic reflector and exits thecompound parabolic reflector through output surface 266 as partiallycollimated light.

Light ray 270 of a first wavelength range is emitted from surface 212 ofemitting layer 208 on the fourth side, passes through the interior oflight-recycling envelope 202 to the wavelength conversion layer 214 onthe second side. Wavelength conversion layer 214 converts light ray 270of a first wavelength range into light ray 272 of a second wavelengthrange. Light ray 272 passes through the interior of the light-recyclingenvelope 202, passes through the light output aperture 204 on the firstside and enters the compound parabolic reflector through input surface264. Light ray 272 is reflected by the sides of the compound parabolicreflector and exits the compound parabolic reflector through outputsurface 266 as partially collimated light.

The degree of light collimation required from the light-collimatingelement depends on the application. The light that exits through thelight output aperture 204 typically has a Lambertian (angles of −90degrees to +90 degrees or a solid angle of 2π) or near Lambertianangular distribution. The degree of collimation exiting thelight-collimating element 262 can be adjusted as needed by changing thearea of the output surface 266 relative to the area of the input surface264 utilizing the mathematical relationship of Equation 5. If the inputrefractive index n_(in) of the light-collimating element is equal to theoutput refractive index n_(out) of the light-collimating element, thenEquation 4 can be used instead and the light output solid angledistribution Ω_(out) from the light-collimating element is given byΩ_(out)=Ω_(in)(Area_(in))/(Area_(out)),  [Equation 7]where Ω_(in) is the light input solid angle distribution into thelight-collimating element, Area_(in) is the area of the input surface264 and Area_(out) is the area of the output surface 266.

For applications requiring a high degree of light collimation, thelight-collimating element 262 partially collimates the light so that thelight output distribution is preferably within the angular range of −30degrees to +30 degrees. More preferably, light-collimating element 262partially collimates the light so that the light output distribution iswithin the angular range of −20 degrees to +20 degrees. Most preferably,light-collimating element 262 partially collimates the light so that thelight output distribution is within the angular range of −10 degrees to+10 degrees.

The embodiments of this invention illustrated in FIGS. 5–7 areillustrated with one LED 206 as the light source. However, embodimentsof this invention may incorporate more than one LED. FIG. 8A illustratesa cross-sectional view of illumination system 280, which has a lightsource consisting of two LEDs that both emit and reflect light.Illumination system 280 is identical to illumination system 200 exceptthat illumination system 280 has an additional LED 282 on the secondside and the area of the wavelength conversion layer is reduced toaccommodate the area of LED 282. LED 282 may emit light of a firstwavelength range or LED 282 may emit light of a third wavelength range,different from the light of a first wavelength range and from the lightof a second wavelength range. LED 282 also reflects light.

In FIG. 8A, part of the light emitted from LED 206 may be reflected byLED 282 and thereby increase the effective brightness of LED 282. Lightray 284 is an illustrative example. Similarly, part of the light emittedfrom LED 282, illustrated by light ray 286, may be reflected by LED 206and thereby increase the effective brightness of LED 206.

If LED 282 emits light of a first wavelength range, then LED 282 adds tothe light of a first wavelength range that is emitted by LED 206. Thewavelength conversion layer 214 will convert a portion of the light of afirst wavelength range from both LEDs into light of a second wavelengthrange. Adding an additional LED 282 that emits light of a firstwavelength range to the illumination system will increase the light fluxand light brightness of the light of a first wavelength range and thelight of a second wavelength range exiting the light output aperture204.

If LED 282 emits light of a third wavelength range, the wavelengths ofthe light of a third wavelength range may be shorter than thewavelengths of the light of a first wavelength range or the wavelengthsof the light of a third wavelength range may be longer than thewavelengths of the light of a second wavelength range. If thewavelengths of the light of a third wavelength range are shorter thanthe wavelengths of the light of a first wavelength range, the wavelengthconversion layer may convert a portion of the light of a thirdwavelength range into light of a second wavelength range. If thewavelengths of the light of a third wavelength range are longer than thewavelengths of the light of a second wavelength range, the wavelengthconversion layer will not convert the light of a third wavelength rangeinto other wavelengths.

If LED 282 emits light of a third wavelength range, the light of a thirdwavelength range can be emitted concurrently with the light of a firstwavelength range emitted by LED 206 and the light of a second wavelengthrange emitted by the wavelength conversion layer. A fraction of thelight of a first wavelength range, a fraction of the light of a secondwavelength range and a fraction of the light of a third wavelength rangewill exit the light output aperture 204 as light of a composite color.By adjusting the electrical power for LED 282 relative to the electricalpower for LED 206, the flux of light of a third wavelength range emittedfrom LED 282 can be varied relative to the flux of light of a firstwavelength range emitted from LED 206 and the corresponding flux oflight of a second wavelength range emitted by the wavelength conversionlayer. By varying the flux of the light of a third wavelength rangeemitted from LED 282, the composite color of the light exiting the lightoutput aperture and the color-rendering index of the light exiting thelight output aperture can be adjusted as desired.

Alternatively, LED 282 can emit light of a third wavelength range in afirst time period and a fraction of the light of third wavelength rangeexits the light output aperture 204 in the first time period. In thefirst time period, LED 206 is not powered and does not emit light. In asecond time period, different from the first time period, LED 206 emitslight of a first wavelength range and a portion of the light of a firstwavelength range is converted to light of second wavelength range. Afraction of the light of a first wavelength range and a fraction of thelight of a second wavelength range exit the light output aperture 204 inthe second time period. In the second time period, LED 282 is notpowered and does not emit light. The first time period and the secondtime period do not overlap. The respective light emissions in the firsttime period and the second time period are then repeated in sequence.The resulting light exiting the light output aperture alternates incolor. Note that if one LED is not powered and does not emit light, itstill functions as a reflector with the reflecting layer reflectinglight incident upon the LED.

FIG. 8B illustrates illumination system 290, which has a light sourcecomprised of three LEDs. Illumination system 290 is identical toillumination system 200 except that illumination system 290 hasadditional LED 292 on the second side and additional LED 294 on thethird side and the area of the wavelength conversion layer is reduced toaccommodate the area of the two additional LEDs. It is also within thescope of this invention that the light source of the illumination systemmay be comprised of more than three LEDs. The total light-emitting areaof all the LEDs in the illumination system is area A_(S). LED 292 emitseither light of a first wavelength range or light of a third wavelengthrange, different from the light of a first or second wavelength range.LED 294 emits light of a first wavelength range, light of a thirdwavelength range, or light of a fourth wavelength range. Light of afourth wavelength range is different than light of a first, second orthird wavelength range. LED 292 and LED 294 may emit light concurrentlywith LED 206 and the wavelength conversion layer 214, or LED 292 and LED294 may emit light in time periods different than the time period forlight emission from LED 206 and wavelength conversion layer 214.

In principle, LEDs may cover the entire inside surface of thelight-recycling envelope with the exception of the area of the lightoutput aperture. However, with this configuration of the wavelengthconversion layer, increasing the area of the LEDs reduces the area ofthe wavelength conversion layer.

In the illumination systems illustrated in FIGS. 5–8, the wavelengthconversion layer 214 covers only the areas of the light-recyclingenvelope that are not occupied by the LEDs and the light output aperture204. It is also within the scope of this invention that the wavelengthconversion layer can have different configurations or shapes.Representative examples are shown in FIGS. 9A, 9B and 9C.

In the cross-sectional view shown in FIG. 9A, wavelength conversionlayer 314 of illumination system 300 coats the exposed surface of LED306 in addition to the inside surfaces of the light-recycling envelope302 not occupied by the LED 306 and the light output aperture 304. Thewavelength conversion layer 314 may coat only a part or substantiallyall of the exposed surface of LED 306, and the wavelength conversionlayer 314 may coat only a part or substantially all of the insidesurfaces of the light-recycling envelope 302 not occupied by the LED 306or the light output aperture 304.

As stated previously, when the wavelength conversion layer coats theemitting layer of an LED, the refractive index difference between theemitting layer and its surroundings is reduced. The reduction in thisrefractive index difference can increase the light emission from theemitting layer and improve the overall efficiency of the illuminationsystem. If desired, the refractive index of the wavelength conversionlayer may be increased further to improve the light emission from theemitting layer by incorporating into the wavelength conversion layerultrafine powders of materials having a bulk index of refractive greaterthan 1.60. Previously noted high-index materials include tin oxide,titanium dioxide, zinc oxide, cerium oxide and antimony pentoxide.

If the wavelength conversion layer 314 coats all exposed surfaces of LED306, light emitted by LED 306 in illumination system 300 must passthrough the wavelength conversion layer 314 at least once in order toexit the light output aperture 304. For example, light ray 316 of afirst wavelength range emitted from surface 312 of emitting layer 308must pass through wavelength conversion layer 314 coating the surface ofLED 306 in order to reach the interior of the light-recycling envelope302. In this example, light ray 316 is not converted to light of asecond wavelength range. Light ray 316 passes through the interior oflight-recycling envelope 302 and exits the illumination system throughlight output aperture 304.

LED 306 has a maximum intrinsic source radiance and a maximum intrinsicsource luminance that are determined by measuring an identicallyconstructed LED that is not coated with a wavelength conversion layerand that is not enclosed in a light-recycling envelope.

Light of a first wavelength range emitted by emitting layer 308 andlight of a second wavelength range emitted by the wavelength conversionlayer 314 may be recycled back to LED 306 by the light-recyclingenvelope and reflect off reflecting layer 310. The recycled light willincrease the effective brightness of LED 306 and, in turn, increase thecombined exiting radiance and combined exiting luminance of light of afirst wavelength range and light of a second wavelength range exitingthe light output aperture 304.

The characteristics and properties of the LED 306, emitting layer 308,reflecting layer 310, the wavelength conversion layer 314, thelight-recycling envelope 302 and the light output aperture 304 inillumination system 300 are identical to the characteristics andproperties of the respective elements in illumination system 200. Thetotal light-emitting area of LED 310 is area A_(S). As noted previously,the reflectivity R_(E) of the light-recycling envelope 302 is preferablyat least 50%. More preferably, the reflectivity R_(E) is at least 70%.Most preferably, the reflectivity R_(E) is at least 90%. Also aspreviously discussed, the reflectivity R_(S) of the reflecting layer 310is preferably at least 50%. More preferably, the reflectivity R_(S) isat least 70%. Most preferably, the reflectivity R_(S) is at least 90%.The total output aperture area of output aperture 304 is area A_(O). Asin illumination system 200, when A_(O) is less than A_(S) and when R_(S)and R_(E) are each greater than 50%, it is possible for the combinedexiting radiance of illumination system 300 to be greater than themaximum intrinsic source radiance of LED 306 and it is also possible forthe combined exiting luminance of illumination system 300 to be greaterthan the maximum intrinsic source luminance of LED 306.

Another embodiment of this invention is illumination system 320. In thecross-sectional view of illumination system 320 shown in FIG. 9B,wavelength conversion layer 322 coats only the exposed surface of theLED 306 and does not coat most portions of the inside surfaces of thelight-recycling envelope 302. It is within the scope of this inventionthat the wavelength conversion layer 322 may coat the entire exposedsurface of LED 306 or may coat only a part of the surface of LED 306.

The characteristics and properties of the LED 306, emitting layer 308,reflecting layer 310, the wavelength conversion layer 322, thelight-recycling envelope 302 and the light output aperture 304 inillumination system 320 are identical to the characteristics andproperties of the respective elements in illumination system 200. Thetotal light-emitting area of LED 310 is area A_(S). As noted previously,the reflectivity R_(E) of the light-recycling envelope 302 is preferablyat least 50%. More preferably, the reflectivity R_(E) is at least 70%.Most preferably, the reflectivity R_(E) is at least 90%. Also aspreviously discussed, the reflectivity R_(S) of the reflecting layer 310is preferably at least 50%. More preferably, the reflectivity R_(S) isat least 70%. Most preferably, the reflectivity R_(S) is at least 90%.The total output aperture area of output aperture 304 is area A_(O). Asin illumination system 200, when A_(O) is less than A_(S) and when R_(S)and R_(E) are each greater than 50%, it is possible for the combinedexiting radiance of illumination system 320 to be greater than themaximum intrinsic source radiance of LED 306 and it is also possible forthe combined exiting luminance of illumination system 320 to be greaterthan the maximum intrinsic source luminance of LED 306.

Another embodiment of this invention is illumination system 340. In thecross-sectional view of illumination system 340 shown in FIG. 9C,wavelength conversion layer 342 fills a substantial portion of thelight-recycling envelope and covers the entire exposed surface of LED306. It is within the scope of this invention that the wavelengthconversion layer 342 may fill only a portion of the light-recyclingenvelope or the wavelength conversion layer 342 may fill a substantialportion of the light-recycling envelope or the wavelength conversionlayer may completely fill the light-recycling envelope.

The characteristics and properties of the LED 306, emitting layer 308,reflecting layer 310, the wavelength conversion layer 342, thelight-recycling envelope 302 and the light output aperture 304 inillumination system 340 are identical to the characteristics andproperties of the respective elements in illumination system 200. Thetotal light-emitting area of LED 306 is area A_(S). As noted previously,the reflectivity R_(E) of the light-recycling envelope 302 is preferablyat least 50%. More preferably, the reflectivity R_(E) is at least 70%.Most preferably, the reflectivity R_(E) is at least 90%. Also aspreviously discussed, the reflectivity R_(S) of the reflecting layer 310is preferably at least 50%. More preferably, the reflectivity R_(S) isat least 70%. Most preferably, the reflectivity R_(S) is at least 90%.The total output aperture area of output aperture 304 is area A_(O). Asin illumination system 200, when A_(O) is less than A_(S) and when R_(S)and R_(E) are each greater than 50%, it is possible for the combinedexiting radiance of illumination system 340 to be greater than themaximum intrinsic source radiance of LED 306 and it is also possible forthe combined exiting luminance of illumination system 340 to be greaterthan the maximum intrinsic source luminance of LED 306.

In FIGS. 5–9, the light source is positioned inside the light-recyclingenvelope. The light-recycling envelope encloses the light source and thewavelength conversion layer. It is also within the scope of thisinvention that a part of the light source may be located outside thelight-recycling envelope. In such cases, the light-recycling envelopepartially encloses the light source but does not enclose the entirelight source. Examples of illumination systems where a part of the lightsource is located outside the light-recycling envelope are shown in thecross-sectional views in FIGS. 10A, 10B and 10C.

FIGS. 10A and 10B show cross-sectional views of illumination system 400.The cross-section of the illumination system 400 has a first side, asecond side, a third side and a fourth side. Illumination system 400 issimilar to illumination system 200 except that the light source forillumination system 400 further comprises a light guide 416 in additionto an LED 406. Illumination system 400 also comprises a light-recyclingenvelope 402, a wavelength conversion layer 414 and a light outputaperture 404 located on the first side of the illumination system. Thecharacteristics and properties of LED 406, the light-recycling envelope402, the wavelength conversion layer 414 and the light output aperture404 are identical to the characteristics and properties of therespective elements in illumination system 200.

LED 406 has a maximum intrinsic source radiance and a maximum intrinsicsource luminance that are determined by measuring an identicallyconstructed LED that is not associated with a light guide and with alight-recycling envelope.

Light guide 416 is located on the fourth side of the illumination systemand has an input surface 418 adjacent to the emitting layer 408 of LED406 and an output surface 420 located inside the light-recyclingenvelope 402. Preferably the area of the input surface 418 is greaterthan the area of surface 412 of the LED 406 so that substantially all ofthe light emitted through the surface 412 of LED 406 will enter lightguide 416. Preferably there is gap between surface 412 of LED 406 andinput surface 418 of light guide 416 and preferably the refractive indexof the gap is less than the refractive index of the light guide. If sucha gap exits and the gap has a refractive index sufficiently smaller thanthe refractive index of the light guide, light emitted from surface 412at large angles, i.e. angles greater than about 45 degrees from thedirection perpendicular to surface 412, will still be accepted intolight guide 416, will be guided by the light guide at angles less thanabout 45 degrees to the direction perpendicular to surface 418 and willbe directed into the light-recycling envelope. Conversely, if no gapexits between surface 412 and surface 418, light emitted from surface412 at angles greater than about 45 degrees from the directionperpendicular to surface 412 probably will not be guided by light guide416 into the light-recycling envelope 402 and probably will be lost.

Light guide 416 transports light of a first wavelength range emitted byemitting layer 408 of LED 406 from LED 406 into the light-recyclingenvelope 402. In addition, light guide 416 transports part of the lightof a first wavelength range and part of the light of a second wavelengthrange from the light-recycling envelope 402 to the reflecting layer 410of LED 406 as recycled light. And finally, light guide 416 transportsthe recycled light reflected by the reflecting layer 410 back into thelight-recycling envelope. Recycled light of a first wavelength range andrecycled light of a second wavelength range reflected from reflectinglayer 410 will increase the effective brightness of LED 406.

The total light-emitting area of LED 406 is area A_(S). As notedpreviously, the reflectivity R_(E) of the light-recycling envelope 402is preferably at least 50%. More preferably, the reflectivity R_(E) isat least 70%. Most preferably, the reflectivity R_(E) is at least 90%.Also as previously discussed, the reflectivity R_(S) of the reflectinglayer 410 is preferably at least 50%. More preferably, the reflectivityR_(S) is at least 70%. Most preferably, the reflectivity R_(S) is atleast 90%. The total output aperture area of output aperture 404 is areaA_(O). As in illumination system 200, when A_(O) is less than A_(S) andwhen R_(S) and R_(E) are each greater than 50%, it is possible for thecombined exiting radiance of illumination system 400 to be greater thanthe maximum intrinsic source radiance of LED 406 and it is also possiblefor the combined exiting luminance of illumination system 400 to begreater than the maximum intrinsic source luminance of LED 406.

Example rays 422, 430 and 432 in FIGS. 10A and 10B illustrate thefunction of light guide 416. Light ray 422 of a first wavelength rangeis emitted from surface 412 of emitting layer 408 of LED 406. Light ray422 passes through the gap between surfaces 412 and 418 and enters lightguide 416 through surface 418. Light ray 422 passes through light guide416, reflecting from a side of light guide 416, and exits light guide416 through surface 420, which is located inside the light-recyclingenvelope 402. Light ray 422 passes through the interior oflight-recycling envelope 402 to wavelength conversion layer 414. In thisexample, conversion layer 414 is a partial reflector in addition tobeing a converting layer. Light ray 422 is reflected by wavelengthconversion layer 414 and passes through the interior of thelight-recycling envelope to exit illumination system 400 through lightoutput aperture 404 as light of a first wavelength range. Note that ifwavelength conversion layer 414 did not reflect light ray 422, light ray422 would have reflected from the light-recycling envelope 402 instead.Light ray 422 was not converted to light of a second wavelength rangeand was not recycled back to reflecting layer 410 of LED 406.

In FIG. 10B, light ray 430 of a first wavelength range is emittedthrough surface 412 of emitting layer 408 of LED 406. Light ray 430passes through the gap between surfaces 412 and 418 and enters lightguide 416 through surface 418. Light ray 430 passes through light guide416, reflecting from the side of light guide 416, and exits light guide416 through surface 420, which is located inside light-recyclingenvelope 402. Light ray 430 passes through the interior oflight-recycling envelope 402 to the wavelength conversion layer 414 onthe first side. Wavelength conversion layer 414 converts light ray 430of a first wavelength range into light ray 432 of a second wavelengthrange. Light ray 432 passes through the interior of light-recyclingenvelope 402 to surface 420 of light guide 416. Light ray 432 passesthrough light guide 416 without reflection, passes through surface 418of light guide 416, passes through surface 412 and emitting layer 408 afirst time, is reflected by reflecting layer 410 and passes throughemitting layer 408 and surface 412 a second time. Light ray 432re-enters light guide 416 through surface 418, passes through lightguide 416 without reflection, and exits light guide 416 through surface420. Light ray 432 then passes through the interior of thelight-recycling envelope to the wavelength conversion layer on thesecond side. Light ray 432 passes through the wavelength conversionlayer 414 a first time, is reflected by the light-recycling envelope 402on the second side, passes through the wavelength conversion layer 414 asecond time, passes through the interior of the light-recycling envelopeand exits illumination system 400 through light output aperture 404 aslight of a second wavelength range.

Overall, wavelength conversion layer 414 converts light ray 430 of afirst wavelength range into light ray 432 of a second wavelength range.Light ray 432 is recycled back to the reflecting layer 410 of LED 406and increases the effective brightness of LED 406.

The light guide 416 may be constructed from any solid material that istransparent to light of a first wavelength range and to light of asecond wavelength range and that transports light by total internalreflection. Possible materials include inorganic glasses such as silicondioxide and plastics such as polymethymethacrylate and fluoroacrylates.If LED 406 emits light in a Lambertian or near-Lambertian output angulardistribution, a light guide 416 that guides light by total internalreflection may need to be a straight light guide in order to preventlight leakage from the sides of the light guide. The light guide 416 mayalso be a solid or hollow structure where the sides, but not the ends,of the light guide are coated with a light reflecting material. If thesides of the light guide 416 are coated with a reflective material, thelight guide 416 may also be a curved light guide and still efficientlytransport light emitted by a Lambertian emitter.

In illumination system 400, the LED is removed from the inside of thelight-recycling envelope. LEDs generate considerable heat duringoperation. Removing the LED from the light-recycling envelope lowers thetemperature inside the light-recycling envelope. Lowering thetemperature is advantageous, especially when multiple LEDs are requiredfor the illumination system. Placing multiple LEDs away from thelight-recycling envelope will allow the LEDs to be operated in apotentially cooler environment, which will increase the light output andthe operating lifetime of the LEDs.

Illumination system 450 shown in cross-section in FIG. 10C is identicalto illumination system 400, except that illumination system 450 includestwo additional light guides, light guide 466 and light guide 486, andtwo additional LEDs, LED 456 and LED 476. The additional LEDs and lightguides may be required if higher light output flux is needed exiting thelight output aperture 404 or if LEDs of different colors are required.

This completes the examples of the first embodiment of this invention.

In the second embodiment of this invention, the output brightness of theillumination system is measured in an identical manner to the outputbrightness in the first embodiment and is measured as the combinedexiting radiance of light of a first wavelength range and light of asecond wavelength range exiting the light output aperture, or as thecombined exiting luminance of light of a first wavelength range andlight of a second wavelength range exiting the light output aperture.However, the reference brightness is different for the second embodimentthan for the first embodiment. The reference brightness for the secondembodiment incorporates the fact that both the light source and thewavelength conversion layer emit light. The reference brightness for thesecond embodiment is the maximum combined intrinsic radiance of light ofa first wavelength range and light of a second wavelength range emittedby the light source and the wavelength conversion layer operating incombination when light recycling is not utilized, or the referencebrightness is the maximum combined intrinsic luminance of light of afirst wavelength range and light of a second wavelength range emitted bythe light source and the wavelength conversion layer operating incombination when light recycling is not utilized.

The reference area used to determine if brightness enhancement is takingplace is also different for the second embodiment. The reference areafor the second embodiment incorporates the fact that since an arealarger than the total light-emitting area of the LEDs emits light, anarea larger than the LED area can be used as the reference area. Thereference area for the second embodiment could be defined as the totallight-emitting area of the light source and wavelength conversion layeroperating in combination. However, determining the total light-emittingarea of the combination may be difficult in some cases since thewavelength conversion layer may have many possible shapes. For example,the wavelength conversion layer may substantially fill thelight-recycling envelope or the wavelength conversion layer may be onlya coating on the light-recycling envelope and/or the light source. Inorder to eliminate any ambiguity in determining the referencelight-emitting area for the light source and wavelength conversion layeroperating in combination, the reference area is chosen to be the maximumcross-sectional area A_(E) of the light-recycling envelope.

Examples of this invention that are related to the second embodiment areillustrated in FIGS. 11–19 and will now be described in detail.

One example of the second embodiment of the present invention isillumination system 500 shown in FIGS. 11A–11F. Illumination system 500is comprised of a light source, a wavelength conversion layer 514, alight-recycling envelope 502 and a light output aperture 504.Illumination system 500 is similar to illumination system 200 in FIGS.5A–5G except that three changes have been made to illumination system500 when compared to illumination system 200. First, in illuminationsystem 500, the light-recycling envelope 502 has a different shape thanlight-recycling envelope 202. Second, in illumination system 500, thewavelength conversion layer 514 substantially fills the light-recyclingenvelope, whereas the wavelength conversion layer in illumination system200 coated the inside surfaces of the light-recycling envelope. Third,in illumination system 500, the position of the LED 506 is changed to aposition opposite the light output aperture.

A top external view of illumination system 500 is illustrated in FIG.11A, showing the outer edge of a light-recycling envelope 502 and alight output aperture 504 as solid lines. FIG. 11B is a cross-sectionalview along the I—I plane indicated in FIG. 11A. FIGS. 11C–11F show thepaths of some representative light rays emitted from LED 506.

The shape of the light-recycling envelope 502 of illumination system 500is an oblate spheroid that has an axis of symmetry 528. Both the shapeof a cross-section of the light-recycling envelope in a planeperpendicular to the axis of symmetry 528 and the shape of the lightoutput aperture 504 are circular. For illumination system 500, theoblate spheroid shape of the surface of the light-recycling envelope502, the circular cross-sectional shape of the light-recycling envelope502 in a plane perpendicular to the axis of symmetry 528 and thecircular shape of the light output aperture 504 are illustrativeexamples used for ease of understanding of the invention and toillustrate alternatives to the shapes illustrated for illuminationsystem 200. It should also be noted that the drawing is merely arepresentation of the structure; the actual and relative dimensions maybe different.

As noted previously, the light-recycling envelope 502 may have anythree-dimensional surface, either regular or irregular, that encloses aninterior volume. The oblate spheroid shape for light-recycling envelope502 was chosen as an illustrative alternative shape to be compared tothe cubical light-recycling envelope 202 in illumination system 200.Similarly, the cross-section of the light-recycling envelope 502 shownin FIG. 11B may have any shape, either regular or irregular, dependingon the shape of the three-dimensional surface of the light-recyclingenvelope 502.

The interior surfaces of a light-recycling envelope generally have across-sectional area that varies depending on the location inside thelight-recycling envelope. However, the interior of a light-recyclingenvelope will have at least one location that has a maximumcross-sectional area, which is denoted as area A_(E). For the symmetricoblate spheroid shape of the light-recycling envelope illustrated inFIGS. 11A and 11B, the maximum cross-sectional area is the circular arealocated at the equator of the oblate spheroid. The circular area has adiameter indicated by line 522. In this example, the plane of themaximum cross-sectional area is perpendicular to the axis of symmetry528 and is parallel to the plane of the light output aperture 504. Forlight-recycling envelopes that have an axis of symmetry that passesthrough one light output aperture, generally the maximum cross-sectionalarea will be in a plane that is perpendicular to the axis of symmetryand parallel to the light output aperture. However, for light-recyclingenvelopes that have irregular shapes or that do not have an axis ofsymmetry, the maximum cross-sectional area may have any arbitraryorientation with respect to the light output aperture.

The oblate spheroid cross-sectional shape of illumination system 500shown in FIG. 11B has a left side, which is to the left of the axis ofsymmetry 528 and a right side, which is to the right of the axis ofsymmetry 528. The light output aperture 504 and the LED 506 are locatedon the axis of symmetry on opposite sides of the light-recyclingenvelope for illustrative purposes only. It is within the scope of thisinvention that the light output aperture 504 may be placed at anylocation in the surface of the light-recycling envelope and the LED 506may be placed at any location on the inside surface of thelight-recycling envelope that does not overlap with the light outputaperture 504.

The inside surfaces of the light-recycling envelope 502, except for thearea occupied by the LED 506 and the area occupied by the light outputaperture 504, are light reflecting surfaces. The light-recyclingenvelope reflects both light of a first wavelength range and light of asecond wavelength range. In order to achieve high light reflectivity,the light-recycling envelope 502 may be fabricated from a bulk materialthat is intrinsically reflective or the inside surfaces of thelight-recycling envelope 502 may be covered with a reflective coating.The bulk material or the reflective coating may be a specular reflector,a diffuse reflector or a diffuse reflector that is backed with aspecular reflecting layer. Examples of reflective materials andreflective coatings were described previously. Preferably thereflectivity R_(E) of the inside surfaces of the light-recyclingenvelope 502 that are not occupied by the LED 506 and the light outputaperture 504 is at least 50%. More preferably, the reflectivity R_(E) isat least 70%. Most preferably, the reflectivity R_(E) is at least 90%.Ideally, the reflectivity R_(E) should be as close to 100% as possiblein order to maximize the efficiency and output brightness of theillumination system.

As illustrated in FIGS. 11A–11F, the wavelength conversion layer 514substantially fills the interior of the light-recycling envelope 502.Alternatively, the wavelength conversion layer 514 may fill only a smallpart of the light-recycling envelope or may entirely fill the parts ofthe light-recycling envelope that are not occupied by LED 506.

The wavelength conversion layer 514 converts a portion of the light of afirst wavelength range emitted by the light source into light of asecond wavelength range, different from the light of a first wavelengthrange. The light of a second wavelength range has longer wavelengths anda lower energy than the light of a first wavelength range, resulting inan energy loss for wavelength conversion. The total energy efficiencyη_(T) of wavelength conversion of light of a first wavelength range tolight of a second wavelength range is given previously by Equation 6.

The wavelength conversion layer 514 is comprised of a powdered phosphormaterial, a quantum dot material, a luminescent dopant material or aplurality of such materials. In addition, the wavelength conversionlayer may further comprise a transparent host material into which thephosphor material, the quantum dot material or the luminescent dopantmaterial is dispersed. Examples of powdered phosphor materials, quantumdot materials, luminescent dopant materials and transparent hostmaterials were listed previously. For illustrative purposes, thewavelength conversion layer 514 in FIGS. 11A–11F is shown to becomprised of particles dispersed in a transparent layer.

Depending on the materials that comprise the wavelength conversion layer514, the wavelength conversion layer may also partially reflect thelight of a first wavelength range and the light of a second wavelengthrange incident upon the wavelength conversion layer. Light may reflectinside the light-recycling envelope by reflecting from thelight-recycling envelope 502, by partially reflecting from thewavelength conversion layer 514 or by reflecting from the light source.Light that passes through the wavelength conversion layer 514 and thatis not reflected or absorbed by the wavelength conversion layer willpass through to the opposite side of the wavelength conversion layer.The wavelength conversion layer is chosen not to interfere with thelight-reflecting properties of the light-recycling envelope and thelight-recycling envelope is chosen not to interfere with the wavelengthconversion properties of the wavelength conversion layer.

Illumination system 500 can have one or more than one light outputaperture. The total output aperture area of all the output apertures inthe illumination system is area A_(O). In FIGS. 11A–11F, illuminationsystem 500 is shown to have just one light output aperture 504 and thearea A_(O) for illumination system 500 is the area of the one lightoutput aperture.

The light source for illumination system 500 is at least one LED. It isalso within the scope of this invention that the light source may be twoor more LEDs. For illustration purposes, the light source forillumination system 500 is shown as one LED, denoted as LED 506, whichis located on the axis of symmetry of the light-recycling envelopeopposite the light output aperture 504. LED 506 may be an inorganiclight-emitting diode or an OLED. Preferably, LED 506 is an inorganiclight-emitting diode. Examples of inorganic light-emitting diodes havebeen listed previously.

The light source and the wavelength conversion layer operating incombination have a maximum combined intrinsic radiance and a maximumcombined intrinsic luminance in the absence of light recycling. Themaximum combined intrinsic radiance and the maximum combined intrinsicluminance may be measured by either removing the light-recyclingenvelope from illumination system 500 and measuring the resultingbrightness or by replacing the light-recycling envelope in illuminationsystem 500 with a light-transparent envelope and then measuring theresulting brightness.

The total light-emitting area of the light source is area A_(S), whichin this example is the light-emitting area of emitting layer 508 of LED506. For examples of the first embodiment, the total light output areaA_(O) must be less than the total light-emitting area A_(S) of thesource in order for brightness enhancement to occur. For examples of thesecond embodiment, however, the critical reference area is the maximumcross-sectional area A_(E) of the light-recycling envelope and not thearea A_(S) of the light source. Since A_(S) is not the critical area inthe second embodiment, the total light-emitting area A_(S) of the lightsource may be less than the area A_(O) of the light output aperture, maybe equal to the area A_(O) of the light output aperture or may begreater than the area A_(O) of the light output aperture. In FIGS.11A–11F, the area of LED 506 is shown for illustrative purposes to beless than the area A_(O) of the light output aperture.

LED 506 has an emitting layer 508 and a reflecting layer 510. Theemitting layer 508 emits light of a first wavelength range. Light may beemitted from emitting layer 508 through one or more surfaces of emittinglayer 508 that are not in contact with reflecting layer 510. Forexample, light may be emitted through surface 512.

The light of a first wavelength range emitted by the emitting layer 508is preferably greater than 200 nanometers in wavelength and less than3000 nanometers in wavelength. More preferably, the light of a firstwavelength range is greater than 200 nanometers in wavelength and lessthan 450 nanometers in wavelength.

The reflecting layer 510 of LED 506 is adjacent to and interior to theinside surface of the light-recycling envelope. The reflecting layer 510reflects both light of a first wavelength range and light of a secondwavelength range. The reflecting layer 510 may be a specular reflectoror a diffuse reflector. In a typical inorganic light-emitting diode, thereflecting layer is usually a specular reflector. The light reflectivityof reflecting layer 510 of LED 506 is R_(S). If the reflectivity variesacross the area of the reflecting layer, the reflectivity R_(S) isdefined as the average reflectivity of the reflecting layer. As listedpreviously, the reflectivity R_(S) of reflecting layer 510 is preferablyat least 50%. More preferably, the reflectivity R_(S) is at least 70%.Most preferably, the reflectivity R_(S) is at least 90%. Ideally, thereflectivity R_(S) should be as close to 100% as possible in order tomaximize the efficiency and output brightness of the illuminationsystem.

The wavelength conversion layer 514 is in contact with LED 506. When thewavelength conversion layer 514 covers all exposed surfaces of LED 506,light emitted by LED 506 in illumination system 500 must pass throughthe wavelength conversion layer 514 at least once in order to reach thelight output aperture 504. As stated previously, when the wavelengthconversion layer covers the emitting layer of an LED, the refractiveindex difference between the emitting layer and its surroundings isreduced. The reduction in the refractive index difference can increasethe light emission from the emitting layer and improve the overallefficiency and output brightness of the illumination system. If desired,the refractive index of the wavelength conversion layer may be increasedfurther to improve the light emission from the emitting layer byincorporating into the wavelength conversion layer ultrafine powders ofmaterials having a bulk index of refractive greater than 1.60.Previously noted ultrafine powder materials include tin oxide, titaniumdioxide, zinc oxide, cerium oxide and antimony pentoxide.

In order to explain the operation of illumination system 500, examplelight rays emitted from LED 506 are illustrated in FIGS. 11C, 11D, 11Eand 11F.

In FIG. 11C, a first light ray 530 of a first wavelength range isemitted from surface 512 of emitting layer 508, passes through thewavelength conversion layer 514 and passes through the remainder of theinterior of the light-recycling envelope to exit the light outputaperture 504 without reflecting off the light-recycling envelope andwithout being converted by the wavelength conversion layer 514.

A second light ray 532 of a first wavelength range is emitted fromsurface 512 of emitting layer 508 and enters the wavelength conversionlayer 514. The wavelength conversion layer 514 converts the light ray532 of a first wavelength range into light ray 534 of a secondwavelength range. The light ray 534 may be emitted in any direction bythe wavelength conversion layer. Light ray 534 passes through theremainder of the wavelength conversion layer 514 and passes through theremainder of the interior of the light-recycling envelope 502 to exitthe illumination system 500 through light output aperture 504 as lightof a second wavelength range.

A third light ray 536 of a first wavelength range is emitted fromsurface 512 of emitting layer 508, passes through the wavelengthconversion layer 514 without being converted, and is absorbed by thelight-recycling envelope 502.

Each time a light ray of a first wavelength range passes through thewavelength conversion layer, the wavelength conversion layer converts aportion of the light of a first wavelength range into light of a secondwavelength range, different from the light of the first wavelengthrange. Each time a light ray of a second wavelength range passes throughthe wavelength conversion layer, the light of a second wavelength rangewill be unaffected. The light of a second wavelength range will notalter its wavelength nor will additional wavelengths be formed.

The probability that a light ray of the first wavelength range will beconverted to a light ray of a second wavelength range upon passagethrough the wavelength conversion layer depends on the type of materialin the wavelength conversion layer, depends on the density of thepowdered phosphor material, the quantum dot material or the luminescentdopant material within the layer and depends on the thickness of thewavelength conversion layer. The probability of wavelength conversioncan be increased either by increasing the density of the powderedphosphor material, the quantum dot material or the luminescent dopantmaterial within the wavelength conversion layer or by increasing thethickness of the layer. However, for some materials such as the quantumdot materials, increasing the density of the material lowers theconversion efficiency of the material due to particle-particleinteractions. In such cases, a low quantum dot material density may bedesired. Then, in order to achieve a high overall conversion efficiencyfor the illumination system, either a thicker wavelength conversionlayer must be used or light recycling must be increased so that light ofa first wavelength range can pass through the wavelength conversionlayer many times.

In FIG. 11C, light ray 530 and light ray 536 are not converted to lightof a second wavelength range. Light ray 532 of a first wavelength rangeis converted into light ray 534 of a second wavelength range. Overall,the wavelength conversion layer converts a portion of the light of afirst wavelength range into light of a second wavelength range,different than the light of the first wavelength range.

Light ray 536 passes through the wavelength conversion layer and isabsorbed by the light-recycling envelope 502. In general, thelight-recycling envelope and the reflecting layer 510 are not perfectreflectors and each has a reflectivity less than 100%. Some of the lightof a first wavelength range, such as light ray 536, and some of thelight of a second wavelength range will be absorbed. Due to theabsorption losses, only a fraction of the light of a first wavelengthrange that is inside the light-recycling envelope will exit thelight-recycling envelope through the light output aperture 504.Likewise, only a fraction of the light of a second wavelength range thatis inside the light-recycling envelope will exit the light-recyclingenvelope through the light output aperture 504.

In FIG. 11D, a fourth light ray 540 of a first wavelength range isemitted from surface 512 of emitting layer 508, passes through thewavelength conversion layer 514 to the light-recycling envelope on theleft side, is reflected by the light-recycling envelope and exitsillumination system 500 through light output aperture 504 as light of afirst wavelength range.

A fifth light ray 542 is emitted from surface 512 of emitting layer 508,passes through a part of the wavelength conversion layer 514 and isconverted by the wavelength conversion layer 514 to light ray 544 of asecond wavelength range. Light ray 544 passes through the remainder ofthe wavelength conversion layer 514, passes through the remainder of thelight-recycling envelope 502, reflects off light-recycling envelope 502and exits illumination system 500 through light output aperture 504 aslight of a second wavelength range.

Light rays 540 and 544 in FIG. 11D illustrate rays that reflect one timeinside the light-recycling envelope. In general, light rays may reflectmany times inside the light-reflecting envelope before either exitingthe illumination system through light output aperture 504 or beingabsorbed by the light-recycling envelope, the LED or the wavelengthconversion material. A multitude of light pathways is possible. Light ofa first wavelength range may be converted to light of a secondwavelength range on the first pass through the wavelength conversionlayer, may be converted only after many passes through the wavelengthconversion layer, or may exit the illumination system without beingconverted. Light that has already been converted to light of a secondwavelength range will not be converted again. The light-recyclingenvelope directs a part of the light of a first wavelength range throughthe wavelength conversion layer multiple times and increases thelikelihood that the light of a first wavelength range will be convertedto light of a second wavelength range.

FIGS. 11E and 11F illustrate light rays that are recycled by thelight-recycling envelope 502 in illumination system 500. Thelight-recycling envelope may recycle light rays back to the wavelengthconversion layer 514 or to the reflecting layer 510.

A sixth light ray 550 of a first wavelength range is emitted fromsurface 512 of emitting layer 508 in a first time period, passes throughthe wavelength conversion layer 514 without being converted, passesthrough the remainder of the interior of the light-recycling envelopeand is reflected and recycled back to the wavelength conversion layer514 by the light-recycling envelope on the left side. The wavelengthconversion layer 514 is a partial reflector in addition to its functionof converting light. The wavelength conversion layer 514 may convertlight ray 550 to light of a second wavelength range, may transmit ray550 to the light-recycling envelope or may reflect light ray 550. InFIG. 11E, the wavelength conversion layer reflects light ray 550 in asecond time period. The reflected light ray 550 then passes through theremainder of the wavelength conversion layer, passes through theremainder of the interior of the light-recycling envelope and exits theillumination system 500 through light output aperture 504 without beingconverted. As illustrated by light ray 550, the light-recycling envelopedirects a part of the light of a first wavelength through the wavelengthconversion layer multiple times and increases the likelihood that thelight of a first wavelength range will be converted into light of asecond wavelength range.

A seventh light ray 552 of a first wavelength range is emitted fromsurface 512 of emitting layer 508 in a first time period, passes partway through the wavelength conversion layer 514 and is converted tolight ray 554. Light ray 554 may be emitted in any direction. In FIG.11E, light ray 554 passes through the remainder of wavelength conversionlayer 514 and reaches the light-recycling envelope on the right side.The light-recycling envelope reflects and recycles light ray 554 back tothe wavelength conversion layer. The wavelength conversion layer 514 maytransmit ray 554 to the light-recycling envelope or may reflect lightray 554. The wavelength conversion layer will not convert light ray 554since light ray 554 has already be converted. In FIG. 11E, thewavelength conversion layer reflects light ray 554 in a second timeperiod. The reflected light ray 554 then passes through the remainder ofthe wavelength conversion layer, passes through the remainder of theinterior of the light-recycling envelope and exits the illuminationsystem 500 through light output aperture 504 as light of a secondwavelength range.

When the light rays 550 and 554 reflect off the wavelength conversionlayer 514 during a second time period, the reflected rays 550 and 554add to the light rays concurrently being emitted by emitting layer 508of LED 506 and emitted by the wavelength conversion layer 514 during thesecond time period. The reflected light rays increase the combinedexiting radiance and the combined exiting luminance of illuminationsystem 500 so that, under some conditions, the combined exiting radianceand the combined exiting luminance can then be higher than therespective maximum combined intrinsic radiance and the maximum combinedintrinsic luminance of illumination system 500 measured in the absenceof light recycling.

In FIG. 11F, an eighth light ray 560 of a first wavelength range isemitted from surface 512 of emitting layer 508 in a first time period.Light ray 560 passes through the wavelength conversion layer 514 withoutbeing converted, passes through the remainder of the interior of thelight-recycling envelope 502 and is reflected and recycled by thelight-recycling envelope back to the wavelength conversion layer 514.Light ray 560 passes through the wavelength conversion layer 514 asecond time without being converted, passes through surface 512 and theemitting layer 508, is reflected by reflecting layer 510 and then passesthrough the emitting layer 508 and through surface 512 during a secondtime period. Light ray 560 passes through the wavelength conversionlayer a third time without being converted, passes through the remainderof the interior of the light-recycling envelope, and exits illuminationsystem 500 through light output aperture 504 as light of a firstwavelength range.

A ninth light ray 562 of a first wavelength range is emitted throughsurface 512 of emitting layer 508 in a first time period. Light ray 562passes through a part of the wavelength conversion layer 514 and isconverted by the wavelength conversion layer into light ray 564 of asecond wavelength range. Light ray 564 passes through the remainder ofwavelength conversion layer 514 and travels to the light-recyclingenvelope 502 on the right side. The light-recycling envelope 502reflects and recycles light ray 564 back toward the wavelengthconversion layer. Light ray 564 passes through the wavelength conversionlayer, passes through surface 512 and through emitting layer 508, isreflected by reflecting layer 510 and passes through emitting layer 508and surface 512 during a second time period. Light ray 564 then passesthrough the wavelength conversion layer and exits the illuminationsystem 500 through the light output aperture 504 as light of a secondwavelength range.

When the light rays 560 and 564 reflect off the light reflecting layer510 and pass through emitting layer 508 and surface 512 during a secondtime period, the reflected rays 560 and 564 add to the light raysconcurrently being emitted by emitting layer 508 of LED 506 and emittedby the wavelength conversion layer during the second time period. Thereflected light rays increase the combined exiting radiance and thecombined exiting luminance of illumination system 500 so that, undersome conditions, the combined exiting radiance and the combined exitingluminance can then be higher than the respective maximum combinedintrinsic radiance and the maximum combined intrinsic luminance ofillumination system 500 measured in the absence of light recycling.

Light rays 530, 532, 534, 536, 540, 542 and 544 are not recycled back tothe wavelength conversion layer 514 or to the light source. Light rays550 and 554 are recycled back to the wavelength conversion layer 514.Light rays 560 and 564 are recycled back to reflecting layer 510 of LED506. Overall, only part of the light of a first wavelength range andonly part of the light of a second wavelength range are recycled back tothe wavelength conversion layer or to the light source.

The light exiting the light output aperture 504 in FIGS. 11C–11F is amixture of light of a first wavelength range and light of a secondwavelength range. If both wavelength ranges are in the visiblewavelength region of the optical spectrum, the mixture of light exitingthe light output aperture will have a composite color. By changing thesize of the light-recycling envelope, changing the thickness of thewavelength conversion layer, changing the composition of the wavelengthconversion layer, changing the characteristics of the light source orchanging the size of the light output aperture, the ratio of the flux oflight of a first wavelength range to the flux of light of a secondwavelength range can be varied. By varying this ratio, the color of thelight exiting the light output aperture can be varied.

If the composite color exiting the light output aperture 504 is whitelight, the quality of the white light can be changed by varying theratio of light of a first wavelength range to light of a secondwavelength range exiting from the light output aperture. The quality ofthe white light can be described by a color-rendering index. Acolor-rendering index of 100 indicates that the white light shining on acolored surface will reproduce the surface colors as seen by the humaneye in an identical manner as if light from the sun were shining on thesurface. A color-rendering index less than 100 indicates that the whitelight shining on a colored surface will give an apparent surface colorthat appears different to the human eye than the color seen by the humaneye using sunlight. By changing the size of the light-recyclingenvelope, changing the thickness of the wavelength conversion layer,changing the composition of the wavelength conversion layer, changingthe characteristics of the light source or changing the size of thelight output aperture, one can vary the number of times that light isrecycled and thereby also vary the ratio of the flux of light of a firstwavelength range to the flux of light of a second wavelength range thatexits the light output aperture. By varying this ratio, thecolor-rendering index of the light exiting the light output aperture canbe improved to achieve the maximum color-rendering index value allowedfor the particular combination of the two wavelength ranges.

As stated previously, illumination system 500 has one light outputaperture 504. The total light output aperture area is area A_(O). It isalso within the scope of this invention that illumination system 500 canhave more than one light output aperture. If there is more than onelight output aperture, the total light output aperture area is alsodefined as area A_(O).

The output radiance of light exiting the light output aperture 504 isdenoted as the combined exiting radiance, and includes both light of afirst wavelength range and light of a second wavelength range. Theoutput luminance of light exiting the light output aperture 504 isdenoted as the combined exiting luminance, and includes both light of afirst wavelength range and light of a second wavelength range.

To determine if illumination system 500 has enhanced output brightness,one must compare the combined output radiance or the combined outputluminance of illumination system 500 to the respective maximum combinedintrinsic radiance or maximum combined intrinsic luminance of areference illumination system. As stated above, the referenceillumination system for the second embodiment of this invention is thelight source and the wavelength conversion material operating incombination with no light-recycling envelope present. Equivalently, thereference illumination system for the second embodiment is the lightsource and the wavelength conversion layer operating in combination butwith the light-recycling envelope replaced by a light-transmittingenvelope that transmits light. The reference LED in the referenceillumination system is substantially identical to LED 506 and isoperating at an electrical power that is substantially identical to theelectrical power used to power LED 506.

In illumination system 500, part of the light of a first wavelengthrange emitted by LED 506 and part of the light of a second wavelengthrange emitted by the wavelength conversion layer 514 are recycled backto LED 506 and to the wavelength conversion layer to increase thecombined radiance or the combined luminance of LED 506 and thewavelength conversion layer operating in combination. By this method,the combined exiting radiance of the light exiting the light outputaperture 504 can also be increased to values greater than the maximumcombined intrinsic radiance of the LED 506 and the wavelength conversionlayer operating in combination in the absence of light recycling. Alsoby this method, the combined exiting luminance of the light exiting thelight output aperture 504 can also be increased to values greater thanthe maximum combined intrinsic luminance of the LED 506 and thewavelength conversion layer operating in combination in the absence oflight recycling.

As in illumination system 200, the maximum reflectivity of the insidesurfaces of illumination system 500 and the resulting maximum values forthe combined exiting radiance and the combined exiting luminance emittedfrom the light output aperture 504 are achieved by preferably havingsubstantially all of the interior surfaces of illumination system 500 bereflective except for the total area A_(O) of all the apertures in thelight-recycling envelope. Illumination system 500 has one light outputaperture 504.

The total inside area of the light-recycling envelope 502 is A_(T). TheLED light source has a reflecting layer having reflectivity R_(S). Thetotal light-emitting area of the light source is area A_(S). In theexample of FIGS. 11A–11F, area A_(S) is the light-emitting area of LED506, but for other examples having more than one LED, A_(S) is the totallight-emitting area of all the LEDs within the light-recycling envelope.The remaining inside area of the light-recycling envelope that is notcovered by the total light-emitting area A_(S) of the LED and the areaA_(O) of the output aperture or apertures is denoted as remaining areaA_(R). It is preferable that substantially all of remaining area A_(R)of the light-recycling envelope have a reflective surface ofreflectivity R_(E) to maximize the radiance and luminance exiting fromthe light output aperture or apertures. As noted previously, thereflectivity R_(E) is preferably at least 50%. More preferably, thereflectivity R_(E) is at least 70%. Most preferably, the reflectivityR_(E) is at least 90%.

As previously discussed, the wavelength conversion layer 514 may alsoreflect light. Light of a first wavelength range and light of a secondwavelength range may be reflected by either the wavelength conversionlayer or the light-recycling envelope 502. However, the reflectivity ofthe wavelength conversion layer 514 is generally less than thereflectivity R_(E) of the light-recycling envelope 502. As long as thewavelength conversion layer has little absorption or no absorption, thetotal reflectivity of the part of the light-recycling envelope that iscovered with the wavelength conversion layer will be substantially thesame as the reflectivity R_(E) of the part of the light-recyclingenvelope that is not covered by the wavelength conversion material.

For examples of the second embodiment, the critical reference area fordetermining if brightness enhancement can occur is the maximumcross-sectional area A_(E) of the light-recycling envelope. In order toachieve radiance enhancement or luminance enhancement, the total outputaperture area A_(O) must be less than the maximum cross-sectional areaA_(E) of the light-recycling envelope.

The maximum theoretical value for brightness enhancement is achievedonly if the LED is a Lambertian emitter and only if R_(S) and R_(E) eachequal 100%. If the LED is not a perfect Lambertian emitter or if R_(S)and R_(E) are each less than 100%, as is normally the case, radiance orluminance enhancement can still be achieved but the magnitude of theenhancement will be reduced. The preferred values for R_(S) and R_(E)were listed previously. In such cases, the area A_(O) may need to besignificantly less than A_(E) in order to achieve a combined exitingradiance that is greater than the maximum combined intrinsic radiance orto achieve a combined exiting luminance that is greater than the maximumcombined intrinsic luminance. Preferably, the area A_(O) of the lightoutput aperture 504 is less than or equal to 50% of the maximumcross-sectional area A_(E) of the light-recycling envelope. Morepreferably, the area A_(O) is less than or equal to 30% of the maximumcross-sectional area A_(E) of the light-recycling envelope. Mostpreferably, the area A_(O) is less than or equal to 10% of the maximumcross-sectional area A_(E) of the light-recycling envelope. In addition,for some applications it is desirable that the area A_(O) of the lightoutput aperture 504 be small and comparable in size to the area of anarc lamp source. For those applications, preferably the area A_(O) ofthe light output aperture 504 is less than 25 mm² in area. Morepreferably, the area A_(O) of the light output aperture 504 is less than₁₀ mm².

Another embodiment of this invention is illumination system 570illustrated in cross-section in FIG. 12. Illumination system 570 iscomprised of a light-recycling envelope 502, an LED 506, a wavelengthconversion layer 514 and a partially reflecting optical element 572.Illumination system 570 is identical to illumination system 500 exceptfor the addition of the partially reflecting optical element 572.Partially reflecting optical element 572 is preferably either areflective polarizer or a dichroic mirror.

As stated previously, a reflective polarizer is a polarizer thatreflects light of a first polarization state and transmits light of asecond polarization state. Polarization states can be states of linearpolarization or states of circular polarization. Examples of suitablereflective polarizers were previously listed. The reflective polarizeris placed adjacent to the light output aperture 504 and placed in theoptical path of light exiting from the light output aperture 504. Theadjacent position of the reflective polarizer can be either just outsidethe light-recycling envelope or just inside the light-recyclingenvelope. The reflective polarizer reflects both light of a firstwavelength range and light of a second wavelength range that have afirst polarization state. Also, the reflective polarizer transmits bothlight of a first wavelength range and light of a second wavelength rangethat have a second polarization state. The light of a first polarizationstate, either light of a first wavelength range or light of a secondwavelength range, is recycled back into the light-recycling envelope.The light of a first polarization state that is recycled back into thelight-recycling envelope will, after multiple reflections, be convertedinto a mixture of light of a first polarization state and light of asecond polarization state. The converted light of a second polarizationstate will then be able to pass through the reflecting polarizer. Ifonly the second polarization state is desired for the output ofillumination system 570, recycling the first polarization state backinto the light-reflecting envelope 502 to be converted to light of asecond polarization state will improve the overall efficiency and outputbrightness of illumination system 570.

Some illumination system applications require polarized light. Forexample, flat-panel display or projection display applications thatincorporate liquid crystal display (LCD) panels orliquid-crystal-on-silicon (LCOS) display panels require polarized light.

As stated previously, a dichroic mirror is, for example, a mirror thatcan reflect light of a first wavelength range and transmit light of asecond wavelength range. Dichroic mirrors may be utilized if light of afirst wavelength range emitted by LED 506 is not desired in the lightoutput from the light-recycling envelope. Dichroic mirrors are commonlyconstructed by alternately depositing layers of two transparentdielectrics having different indexes of refraction onto a transparentsubstrate. Examples of materials used for dielectric coating layersinclude silicon dioxide, titanium dioxide or magnesium fluoride.

When the partially transparent optical element 572 is a dichroic mirror,the dichroic mirror is placed adjacent to the light output aperture 504and placed in the optical path of light exiting from the light outputaperture 504. The adjacent position of the dichroic mirror can be eitherjust outside the light-recycling envelope or just inside thelight-recycling envelope. In FIG. 12, the partially reflecting opticalelement is a dichroic mirror and is positioned just outside the lightoutput aperture 504.

The function of the dichroic mirror in FIG. 12 is illustrated usinglight rays 574, 576 and 578. Light ray 574 of a first wavelength rangeis emitted from surface 512 of emitting layer 508, passes through thewavelength conversion layer 514 and the interior of the light-recyclingenvelope 502 and passes through the light output aperture 504 a firsttime to reach the partially reflecting optical element 572, which inthis example is a dichroic mirror. Light ray 574 reflects off thedichroic mirror, passes through the light output aperture 504 a secondtime and is recycled back into the interior of the light-recyclingenvelope 502.

Light ray 576 of a first wavelength range is emitted from surface 512 ofemitting layer 508 and passes through a part of the wavelengthconversion layer 514. The wavelength conversion layer 514 converts lightray 576 of a first wavelength range into light ray 578 of a secondwavelength range. Light ray 578 may be emitted in any direction. In thisexample, light ray 578 passes through the remainder of the wavelengthconversion layer, passes through the remainder of the interior of thelight-recycling envelope 502, passes through the light output aperture504 and passes through the partially reflecting optical element 572,which is the dichroic mirror.

Overall, the dichroic mirror transmits light of a second wavelengthrange and reflects light of a first wavelength range back into thelight-recycling envelope. The wavelength conversion layer can convertthe light of a first wavelength range that is recycled back into thelight-recycling envelope into light of a second wavelength range. Theconverted light of a second wavelength range can then pass through thedichroic mirror. If only light of a second wavelength range is desiredfor the output of illumination system 570, recycling the light of afirst wavelength range back into the light-reflecting envelope to beconverted into light of a second wavelength range will improve theoverall efficiency and output brightness of illumination system 570.

Another embodiment of this invention is illumination system 580 shown incross-section in FIG. 13. Illumination system 580 is identical toillumination system 500 except that illumination system 580 furthercomprises a light-collimating element 582. Light-collimating element 582can be any optical element that at least partially collimates the lightexiting from the light output aperture 504. For example, thelight-collimating element can be a convex lens, a tapered light guide,or a compound parabolic reflector.

In FIG. 13, light-collimating element 582 is a compound parabolicreflector for illustrative purposes. Compound parabolic reflectors havebeen described previously. Light-collimating element 582 has an inputsurface 584 and an output surface 586. In order for thelight-collimating element to partially collimate the light exiting thelight output aperture 504, the area of input surface 584 must be lessthan the area of the output surface 586. Equation 7 gives themathematical relationship between the input and output areas and theinput and output angular distributions of the light.

Representative light rays 590, 592 and 594 are shown in FIG. 13 toillustrate the function of the light-collimating element 582 whenlight-collimating element 582 is a compound parabolic reflector. Lightray 590 of a first wavelength range is emitted from surface 512 ofemitting layer 508, passes through the wavelength conversion layer 514and the interior of the light-recycling envelope 502, passes through thelight output aperture 504 and passes through input surface 584 of thecompound parabolic reflector as uncollimated light. Light ray 590 isreflected by the sides of the compound parabolic reflector and exits thecompound parabolic reflector through output surface 586 as partiallycollimated light.

Light ray 592 of a first wavelength range is emitted from surface 512 ofemitting layer 508 and passes through part of the wavelength conversionlayer 514. The wavelength conversion layer 514 converts light ray 592 ofa first wavelength range into light ray 594 of a second wavelengthrange. Light ray 594 passes through the remainder of the wavelengthconversion layer and the remainder of the interior of thelight-recycling envelope 502, passes through the light output aperture504 and enters the compound parabolic reflector through input surface584. Light ray 594 is reflected by the sides of the compound parabolicreflector and exits the compound parabolic reflector through outputsurface 586 as partially collimated light. The preferences for thedegree of light collimation have been described previously in theexplanation for FIG. 7.

The examples of the second embodiment shown in FIGS. 11–13 areillustrated with one LED 506 as the light source. However, embodimentsof this invention may incorporate more than one LED. FIG. 14 illustratesillumination system 1000, which has a light source consisting of threeLEDs and where each LED reflects light. The total light-emitting area ofthe light source is the total light-emitting area of the three LEDs andis area A_(S). Illumination system 1000 is identical to illuminationsystem 500 except that illumination system 1000 has two additional LEDs,LED 1006 and LED 1026. LED 1006 may emit light of a first wavelengthrange or LED 1006 may emit light of a third wavelength range, where thelight of a third wavelength range is different from the light of thefirst and second wavelength ranges. LED 1026 may emit light of a firstwavelength range, LED 1026 may emit light of a third wavelength range,different from the light of the first and second wavelength ranges, orLED 1026 may emit light of a fourth wavelength range, different from thelight of the first, second and third wavelength ranges.

In FIG. 14, some of the light emitted from LED 1006, LED 1026 and thewavelength conversion layer 514 is directed to or recycled back to LED506 and is reflected by LED 506 to increase the effective brightness ofLED 506. Similarly, some of the light emitted from LED 506, LED 1026 andthe wavelength conversion layer 514 is directed to or recycled back toLED 1006 and is reflected by LED 1006 to increase the effectivebrightness of LED 1006. In addition, some of the light emitted by LED506, LED 1006 and the wavelength conversion layer 514 is directed to orrecycled back to LED 1026 and is reflected by LED 1026 to increase theeffective brightness of LED 1026.

If LED 1006 or LED 1026 emits light of a first wavelength range, thenthe additional light of a first wavelength range adds to the light of afirst wavelength range that is emitted by LED 506. The wavelengthconversion layer 514 will convert a portion the light of a firstwavelength range from each LED that emits light of a first wavelengthrange into light of a second wavelength range. Adding an additional LEDthat emits light of a first wavelength range to the illumination systemwill increase the light flux and light brightness of the light of afirst wavelength range and the light of a second wavelength rangeexiting the light output aperture 504.

If LED 1006 or LED 1026 emits light of a third wavelength range, thewavelengths of the light of a third wavelength range may be shorter thanthe wavelengths of the light of a first wavelength range or thewavelengths of the light of a third wavelength range may be longer thanthe wavelengths of the light of a second wavelength range. If thewavelengths of the light of a third wavelength range are shorter thanthe wavelengths of the light of a first wavelength range, the wavelengthconversion layer may convert a portion of the light of a thirdwavelength range into light of a second wavelength range. If thewavelengths of the light of a third wavelength range are longer than thewavelengths of the light of a second wavelength range, the wavelengthconversion layer will not convert the light of a third wavelength rangeinto other wavelengths.

If LED 1006 or LED 1026 emits light of a third wavelength range, thelight of a third wavelength range can be emitted concurrently with thelight of a first wavelength range emitted by LED 506 and the light of asecond wavelength range emitted by the wavelength conversion layer. Afraction of the light of a first wavelength range, a fraction of thelight of a second wavelength range and a fraction of the light of athird wavelength range will exit the light output aperture 504 as lightof a composite color. By adjusting the electrical power for LED 1006 orLED 1026 relative to the electrical power for LED 506, the flux of lightof a third wavelength range emitted from LED 1006 or LED 1026 can bevaried relative to the flux of light of a first wavelength range emittedfrom LED 506. By varying the flux of the light of a third wavelengthrange emitted from LED 1006 or LED 1026, the composite color of thelight exiting the light output aperture and the color-rendering index ofthe light exiting the light output aperture can be adjusted as desired.In particular, the color-rendering index can be adjusted to achieve themaximum value possible for the exiting wavelengths.

Alternatively, LED 1006 or LED 1026 can emit light of a third wavelengthrange in a first time period and a fraction of the light of thirdwavelength range exits the light output aperture 504 in the first timeperiod. In the first time period, LED 506 is not powered and does notemit light. In a second time period, different than the first timeperiod, LED 506 emits light of a first wavelength range and a portion ofthe light of a first wavelength range is converted to light of secondwavelength range. A fraction of the light of a first wavelength rangeand a fraction of the light of a second wavelength range exit the lightoutput aperture 504 in the second time period. In the second timeperiod, the LED that emits light of a third wavelength range is notpowered and does not emit light. The first and second time periods donot overlap. The respective light emissions in the first time period andthe second time period are then repeated in sequence. The resultinglight exiting the light output aperture alternates in color. Note thatif one LED is not powered and does not emit light, it still functions asa reflector with the reflecting layer reflecting light incident upon theLED.

If LED 1026 emits light of a fourth wavelength range, different from thelight of the first, second and third wavelength ranges, the light of afourth wavelength range may be emitted concurrently with the light ofthe other LEDs or the light may be emitted in time periods differentthan the time periods for light emission from LED 506 and LED 1006.

In FIGS. 11–14, the light source is positioned inside thelight-recycling envelope. The light-recycling envelope encloses thelight source and the wavelength conversion layer. It is also within thescope of the second embodiment of this invention that a part of thelight source may be located outside the light-recycling envelope aspreviously described in FIGS. 10A, 10B and 10C for examples of the firstembodiment. In such cases, the light-recycling envelope partiallyencloses the light source but does not enclose the entire light source.Examples of illumination systems where a part of the light source islocated outside the light-recycling envelope are shown in thecross-sectional views in FIGS. 15 and 16.

FIG. 15 shows a cross-sectional view of illumination system 600.Illumination system 600 is similar to illumination system 500 exceptthat the light source for illumination system 600 comprises a lightguide 626 in addition to an LED 606. LED 606 has an emitting layer 608and a reflecting layer 610. Illumination system 600 also comprises alight-recycling envelope 602, a wavelength conversion layer 614 and alight output aperture 604. The characteristics and properties ofelements 606, 608, 610, 602, 614 and 604 are identical to thecharacteristics and properties of the respective elements inillumination system 500. The light-recycling envelope 602 has a maximumcross-sectional area A_(E). The light source, comprising LED 606 andlight guide 626, and the wavelength conversion layer 614 operating incombination have a maximum combined intrinsic radiance and a maximumcombined intrinsic luminance in the absence of light recycling.

Light guide 626 is located between the LED 606 and the light-recyclingenvelope. Light guide 626 has an input surface 628 adjacent to thesurface 612 of emitting layer 608 of LED 606 and an output surface 630located inside the light-recycling envelope 602. The light guide can bea solid light guide that guides light by total internal reflection.Alternatively, the light guide can be a solid or hollow light guide thathas reflecting coatings on the sides to guide the light. Preferably thearea of the input surface 628 is greater than the area of surface 612 ofthe LED 606 so that substantially all of the light emitted through thesurface 612 of LED 606 will enter light guide 626. If the light guide isa solid light guide that guides light by total internal reflection,preferably there is gap between the surface 612 of LED 606 and the inputsurface 628 of light guide 626 and preferably the refractive index ofthe gap is less than the refractive index of the light guide. If such agap exits and the gap has a refractive index sufficiently smaller thanthe refractive index of the light guide, light emitted from surface 612at large angles, i.e. angles greater than about 45 degrees from thedirection perpendicular to surface 612, will still be accepted intolight guide 626, will be guided through the light guide at angles lessthan about 45 degrees to the direction perpendicular to surface 628 andthen will be directed into the light-recycling envelope. Conversely, ifno gap exists between surface 612 and surface 628, light emitted fromsurface 612 at angles greater than about 45 degrees from the directionperpendicular to surface 612 probably will not be guided by light guide626 into the light-recycling envelope 602 and will be lost.

Light guide 626 transports light of a first wavelength range emitted byemitting layer 608 of LED 606 from LED 606 into the light-recyclingenvelope 602. In addition, light guide 626 transports light of a firstwavelength range and light of a second wavelength range from thelight-recycling envelope 602 to the reflecting layer 610 of LED 606 asrecycled light. And finally, light guide 626 transports the recycledlight reflected by the reflecting layer 610 back into thelight-recycling envelope. Recycled light of a first wavelength range andrecycled light of a second wavelength range reflected from reflectinglayer 610 will increase the effective brightness of LED 606 and improvethe efficiency and output brightness of illumination system 600.

As noted previously, the reflectivity R_(E) of the light-recyclingenvelope 602 is preferably at least 50%. More preferably, thereflectivity R_(E) is at least 70%. Most preferably, the reflectivityR_(E) is at least 90%. Also as previously discussed, the reflectivityR_(S) of the reflecting layer 610 is preferably at least 50%. Morepreferably, the reflectivity R_(S) is at least 70%. Most preferably, thereflectivity R_(S) is at least 90%. The total output aperture area ofoutput aperture 604 is area A_(O). As in illumination system 500, whenA_(O) is less than A_(E) and when R_(S) and R_(E) are each greater than50%, it is possible for the combined exiting radiance of illuminationsystem 600 to be greater than the maximum combined intrinsic radiance ofthe light source, comprising LED 606 and light guide 626, and thewavelength conversion layer 614 operating in combination. It is alsopossible for the combined exiting luminance of illumination system 600to be greater than the maximum combined intrinsic luminance of the lightsource, comprising LED 606 and light guide 626, and the wavelengthconversion layer 614 operating in combination.

Example rays 632 and 634 illustrate part of the function of light guide626 and also illustrate an example of light recycling. Light ray 632 isemitted from surface 612 of emitting layer 608 in a first time period,enters light guide 626 through input surface 628, is reflected by thesides of light guide 626 and exits light guide 626 through outputsurface 630. Light ray 632 passes through part of the wavelengthconversion layer 614. Wavelength conversion layer 614 converts light ray632 of a first wavelength range into light ray 634 of a secondwavelength range. Light ray 634 passes through the remainder ofwavelength conversion layer 614, passes through part of the interior ofthe light-recycling envelope 602 and is reflected and recycled back tothe wavelength conversion layer 614 by the light-recycling envelope.Light ray 634 reenters the wavelength conversion layer 614. Light ray634 may now take one of many pathways. For example, the wavelengthconversion layer 614 could reflect light ray 634, light ray 634 couldpass through the wavelength conversion layer and be reflected by thelight-recycling envelope, or light ray 634 could pass through thewavelength conversion layer and the light guide 626, be reflected byreflecting layer 610 of LED 608 and return through light guide 626 tothe wavelength conversion layer 614. In FIG. 15, light ray 634 isreflected by wavelength conversion layer 614 in a second time period andexits the light output aperture 604 as light of a second wavelengthrange.

When light ray 634 is recycled back to the wavelength conversion layer614 or to the reflecting layer 610 of LED 608 in a second time period,light ray 634 adds to the light concurrently being emitted by LED 608and the wavelength conversion layer 614 in the second time period. Whensuch recycling occurs, it is possible for the combined exiting radianceof light exiting the light output aperture 604 to be greater than themaximum combined intrinsic radiance of the light source and thewavelength conversion layer operating in combination in the absence ofrecycling. In addition, it is possible for the combined exitingluminance of light exiting the light output aperture 604 to be greaterthan the maximum combined intrinsic luminance of the light source andthe wavelength conversion layer operating in combination in the absenceof recycling.

The light guide 626 may be constructed from any solid material that istransparent to light of a first wavelength range and to light of asecond wavelength range and that transports light by total internalreflection. Possible materials include inorganic glasses such as silicondioxide and plastics such as polymethymethacrylate and fluoroacrylates.If LED 606 emits light in a Lambertian or near-Lambertian output angulardistribution, a light guide 626 that guides light by total internalreflection may need to be a straight light guide in order to preventlight leakage from the sides of the light guide. Alternatively, thelight guide 626 may also be a solid or hollow structure where the sides,but not the ends, of the structure are coated with a light reflectingmaterial. If the sides of a light guide are coated with a reflectivematerial, the light guide may be a curved light guide and stillefficiently transport light emitted by a Lambertian emitter.

In illumination system 600, the LED is removed from the inside of thelight-recycling envelope. As discussed previously, LEDs generateconsiderable heat during operation. Removing the LED from thelight-recycling envelope lowers the temperature inside thelight-recycling envelope. Lowering the temperature is advantageous,especially when multiple LEDs are required for the illumination system.Placing multiple LEDs away from the light-recycling envelope will allowthe LEDs to be operated in a potentially cooler environment, which willincrease the light output and the operating lifetime of the LEDs.

Another embodiment of this invention, illumination system 650 in FIG.16, is identical to illumination system 600, except that illuminationsystem 650 includes two additional light guides, light guide 666 andlight guide 686, and two additional LEDs, LED 656 and LED 676. Theadditional LEDs and light guides may be required if higher light outputflux is needed exiting the light output aperture 604.

In the illumination systems illustrated in FIGS. 11–16, the wavelengthconversion layer 514 or 614 fills a substantial portion of thelight-recycling envelope. It is also within the scope of this inventionthat the wavelength conversion layer can have different configurationsor shapes. Representative examples are shown in FIGS. 17, 18 and 19.

In the cross-sectional view shown in FIG. 17, wavelength conversionlayer 714 of illumination system 700 coats the exposed surfaces of LED706 and the inside surfaces of the light-recycling envelope 702 notoccupied by the LED 706 and the light output aperture 704. Thewavelength conversion layer 714 may coat only a part or substantiallyall of the exposed surface of LED 706, and the wavelength conversionlayer 714 may coat only a part or substantially all of the insidesurfaces of the light-recycling envelope 702 not occupied by the LED 706or the light output aperture 704.

The LED 706 is comprised of emitting layer 708 and reflecting layer 710.The reflectivity of reflecting layer 710 is R_(S). Preferred values forR_(S) were listed previously. The LED 706 and the wavelength conversionlayer 714 operating in combination have a maximum combined intrinsicradiance and a maximum combined intrinsic luminance in the absence ofrecycling. The absence of recycling is achieved if the light-recyclingenvelope is removed or if the light-recycling envelope is replaced witha light-transmitting envelope that transmits light of a first wavelengthrange and light of a second wavelength range.

The light-recycling envelope has a maximum cross-sectional area A_(E).The reflectivity of the inside surfaces of the light-recycling envelopenot occupied by the LED 706 and the light output aperture 704 isreflectivity R_(E). Preferred values for R_(E) were listed previously.The light-recycling envelope reflects and recycles light emitted by LED706 and the wavelength conversion layer 714 back to the LED 706 and thewavelength conversion layer 714. The recycled light will add to thelight concurrently being emitted by the LED 706 and the wavelengthconversion layer and, in turn, increase the combined exiting radianceand combined exiting luminance of light of a first wavelength range andlight of a second wavelength range exiting the light output aperture704.

The characteristics and properties of the LED 706, emitting layer 708,reflecting layer 710, the wavelength conversion layer 714, thelight-recycling envelope 702 and the light output aperture 704 inillumination system 700 are identical to the characteristics andproperties of the respective elements in illumination system 500. Thetotal output aperture area of output aperture 704 is area A_(O). WhenA_(O) is less than A_(E) and when R_(S) and R_(E) are each greater than50%, it is possible for the combined exiting radiance of illuminationsystem 700 to be greater than the maximum combined intrinsic radiance ofLED 706 and the wavelength conversion layer 714 operating incombination. It is also possible for the combined exiting luminance ofillumination system 700 to be greater than the maximum combinedintrinsic luminance of LED 706 and the wavelength conversion layer 714operating in combination.

Another example of the second embodiment of this invention isillumination system 800. In the cross-sectional view of illuminationsystem 800 shown in FIG. 18, wavelength conversion layer 814 coats theexposed surfaces of LED 806 and does not coat most portions of theinside surfaces of the light-recycling envelope 802. It is within thescope of this invention that the wavelength conversion layer 814 maycoat the entire exposed surfaces of LED 806 or may coat only a part ofthe exposed surfaces of LED 806.

The LED 806 is comprised of emitting layer 808 and reflecting layer 810.The reflectivity of reflecting layer 810 is R_(S). Preferred values forR_(S) were listed previously. The LED 806 and the wavelength conversionlayer 814 operating in combination have a maximum combined intrinsicradiance and a maximum combined intrinsic luminance when thelight-recycling envelope is removed or when the light-recycling envelopeis replaced with light-transmitting envelope that transmits light of afirst wavelength range and light of a second wavelength range.

The light-recycling envelope has a maximum cross-sectional area A_(E).The reflectivity of the inside surfaces of the light-recycling envelopenot occupied by the LED 806 and the light output aperture 804 isreflectivity R_(E). Preferred values for R_(E) were listed previously.The light-recycling envelope reflects and recycles light emitted by LED806 and the wavelength conversion layer 814 back to the LED 806 and thewavelength conversion layer 814. The recycled light will add to thelight concurrently being emitted by the LED 806 and the wavelengthconversion layer 814 and, in turn, increase the combined exitingradiance and combined exiting luminance of light of a first wavelengthrange and light of a second wavelength range exiting the light outputaperture 804.

The characteristics and properties of the LED 806, emitting layer 808,reflecting layer 810, the wavelength conversion layer 814, thelight-recycling envelope 802 and the light output aperture 804 inillumination system 800 are identical to the characteristics andproperties of the respective elements in illumination system 500. Thetotal light output aperture area of light output aperture 804 is areaA_(O). When A_(O) is less than A_(E) and when R_(S) and R_(E) are eachgreater than 50%, it is possible for the combined exiting radiance ofillumination system 800 to be greater than the maximum combinedintrinsic radiance of LED 806 and the wavelength conversion layer 814operating in combination. It is also possible for the combined exitingluminance of illumination system 800 to be greater than the maximumcombined intrinsic luminance of LED 806 and the wavelength conversionlayer 814 operating in combination.

Another embodiment of this invention is illumination system 900. In thecross-sectional view of illumination system 900 shown in FIG. 19,wavelength conversion layer 914 covers only the inside surfaces of thelight-recycling envelope not occupied by the LED 906 or the light outputaperture 904. The wavelength conversion layer 914 does not coveremitting layer 908 of LED 906. It is also within the scope of thisinvention that the wavelength conversion layer 914 may cover only partof the light-recycling envelope 902.

The LED 906 is comprised of emitting layer 908 and reflecting layer 910.The reflectivity of reflecting layer 910 is R_(S). Preferred values forR_(S) were listed previously. The LED 906 and the wavelength conversionlayer 914 operating in combination have a maximum combined intrinsicradiance and a maximum combined intrinsic luminance when thelight-recycling envelope is removed or when the light-recycling envelopeis replaced with light-transmitting envelope that transmits light of afirst wavelength range and light of a second wavelength range.

The light-recycling envelope has a maximum cross-sectional area A_(E).The reflectivity of the inside surfaces of the light-recycling envelopenot occupied by the LED 906 and the light output aperture 904 isreflectivity R_(E). Preferred values for R_(E) were listed previously.The light-recycling envelope reflects and recycles light emitted by LED906 and the wavelength conversion layer 914 back to the LED 906 and thewavelength conversion layer 914. The recycled light will add to thelight concurrently being emitted by the LED 906 and the wavelengthconversion layer 914 and, in turn, increase the combined exitingradiance and combined exiting luminance of light of a first wavelengthrange and light of a second wavelength range exiting the light outputaperture 904.

The characteristics and properties of the LED 906, emitting layer 908,reflecting layer 910, the wavelength conversion layer 914, thelight-recycling envelope 902 and the light output aperture 904 inillumination system 900 are identical to the characteristics andproperties of the respective elements in illumination system 500. Thetotal light output aperture area of light output aperture 904 is areaA_(O). When A_(O) is less than A_(E) and when R_(S) and R_(E) are eachgreater than 50%, it is possible for the combined exiting radiance ofillumination system 900 to be greater than the maximum combinedintrinsic radiance of LED 906 and the wavelength conversion layer 914operating in combination. It is also possible for the combined exitingluminance of illumination system 900 to be greater than the maximumcombined intrinsic luminance of LED 906 and the wavelength conversionlayer 914 operating in combination.

This completes the examples of the second embodiment of this invention.

In examples of the third embodiment of this invention, the light sourcefor the illumination system is at least one semiconductor laser thatemits light of a first wavelength range. The light emitted by asemiconductor laser is generally very bright and is emitted over arelatively small angular range. Also, the light source emitting area isusually small. When a light-recycling envelope is used to partiallyenclose a semiconductor laser and a wavelength conversion layer, it isnot expected that the light-recycling envelope will significantlyenhance the output brightness of light of a first wavelength rangeexiting the light output aperture of the illumination system. However,examples of the third embodiment are designed so that thelight-recycling envelope will enhance the brightness of light of asecond wavelength range exiting the light output aperture of theillumination system compared to the brightness of light of a secondwavelength range generated in the absence of recycling.

Accordingly, in the third embodiment of this invention, the outputbrightness of the illumination system is not measured in the same way asfor the first and second embodiments. In the third embodiment, theoutput brightness is measured as the exiting radiance of light of asecond wavelength range exiting the light output aperture, or the outputbrightness is measured as the exiting luminance of light of a secondwavelength range exiting the light output aperture. Any light of a firstwavelength range exiting the light output aperture is ignored in theoutput brightness measurement. This measurement can be done by using adichroic mirror or an optical bandpass filter to block light of a firstwavelength range from reaching the measurement detector.

The reference brightness is also measured differently for examples ofthe third embodiment than for examples of the first and secondembodiments. The reference brightness for the third embodimentincorporates the fact that the light source is needed in order for thewavelength conversion layer to emit light. The reference brightness forthe third embodiment is measured as the maximum combined intrinsicradiance of light of a second wavelength range emitted by the lightsource and the wavelength conversion layer operating in combination whenlight recycling is not utilized, or the reference brightness is measuredas the maximum combined intrinsic luminance of light of a secondwavelength range emitted by the light source and the wavelengthconversion layer operating in combination when light recycling is notutilized. Any light of the first wavelength range that is present isignored in the reference measurement.

For examples of the third embodiment, the reference area that is used todetermine if brightness enhancement is taking place is the samereference area that is used for the second embodiment. The referencearea for examples of the third embodiment incorporates the fact thatsince an area larger than the total light-emitting area of thesemiconductor laser emits light, an area larger than the semiconductorlaser output area should be used as the reference area. In order toeliminate any ambiguity in determining the reference light-emitting areafor the light source and wavelength conversion layer operating incombination, the reference area is chosen to be the maximumcross-sectional area A_(E) of the light-recycling envelope. This areawas chosen because the wavelength conversion layer may have manypossible configurations and shapes and the cross-sectional area of thewavelength conversion layer may be difficult to determine.

Examples of this invention illustrated in FIGS. 20–22 that are includedin the third embodiment will now be described in detail.

One example of the third embodiment of the present invention isillumination system 1100 shown in FIGS. 20A–20C. Illumination system1100 is comprised of a light source, a wavelength conversion layer 1114,a light-recycling envelope 1102 and a light output aperture 1104.Illumination system 1100 is similar to illumination system 500 in FIGS.11A–11F except that two changes have been made to illumination system1100 in comparison to illumination system 500. First, in illuminationsystem 1100, the light source is changed to a semiconductor laserinstead of an LED. Second, the position of the light source, i.e. thesemiconductor laser 1106, in illumination system 1100 is changed to aposition on the left side of the light-recycling envelope and is nolonger on the axis of symmetry 1128.

A top external view of illumination system 1100 is illustrated in FIG.20A, showing the outer edge of a light-recycling envelope 1102 and alight output aperture 1104 as solid lines. FIG. 20B is a cross-sectionalview along the I—I plane indicated in FIG. 20A: FIG. 20C show the pathsof some representative light rays emitted from semiconductor laser 1106.

The shape of the light-recycling envelope 1102 of illumination system1100 is the same as the shape of the light-recycling envelope 502 inillumination system 500. The shape is an oblate spheroid that has anaxis of symmetry 1128. Both the shape of a cross-section of thelight-recycling envelope in a plane perpendicular to the axis ofsymmetry 1128 and the shape of the light output aperture 1104 arecircular. For illumination system 1100, the oblate spheroid shape of thesurface of the light-recycling envelope 1102, the circularcross-sectional shape of the light-recycling envelope 1102 in a planeperpendicular to the axis of symmetry 1128 and the circular shape of thelight output aperture 1104 are illustrative examples used for ease ofunderstanding of the invention. It should also be noted that the drawingis merely a representation of the structure; the actual and relativedimensions may be different.

As noted previously in other examples, the light-recycling envelope 1102may have any three-dimensional surface, either regular or irregular,that encloses an interior volume. Similarly, the cross-section of thelight-recycling envelope 1102 shown in FIG. 20B may have any shape,either regular or irregular, depending on the shape of thethree-dimensional surface of the light-recycling envelope 1102.

The interior surfaces of a light-recycling envelope generally have across-sectional area that varies depending on the location inside thelight-recycling envelope. However, the interior of a light-recyclingenvelope will have at least one location that has a maximumcross-sectional area, which is denoted as area A_(E). For the symmetricoblate spheroid shape of the light-recycling envelope illustrated inFIGS. 20A–20C, the maximum cross-sectional area is a circular area ofdiameter 1122 located at the equator of the oblate spheroid. In thisexample, the plane of the maximum cross-sectional area is perpendicularto the axis of symmetry 1128 and is parallel to the plane of the lightoutput aperture 1104. For light-recycling envelopes that have an axis ofsymmetry that passes through one light output aperture, the maximumcross-sectional area will usually be in a plane that is perpendicular tothe axis of symmetry and parallel to the light output aperture. However,for light-recycling envelopes that have irregular shapes or that do nothave an axis of symmetry, the maximum cross-sectional area may have anarbitrary orientation with respect to a light output aperture.

The oblate spheroid cross-sectional shape of illumination system 1100shown in FIG. 20B has a left side, which is to the left of the axis ofsymmetry 1128 and a right side, which is to the right of the axis ofsymmetry 1128. The light output aperture 1104 is located on the axis ofsymmetry for illustrative purposes only. It is within the scope of thisinvention that the light output aperture 1104 may be placed at anylocation in the surface of the light-recycling envelope and thesemiconductor laser 1106 may be placed at any location on the insidesurfaces of the light-recycling envelope that does not overlap with thelight output aperture.

The inside surfaces of the light-recycling envelope 1102, except for thearea occupied by the semiconductor laser 1106 and the area occupied bythe light output aperture 1104, are light reflecting surfaces. Thelight-recycling envelope reflects both light of a first wavelength rangeand light of a second wavelength range. In order to achieve high lightreflectivity, the light-recycling envelope 1102 may be fabricated from abulk material that is intrinsically reflective or the inside surfaces ofthe light-recycling envelope 1102 may be covered with a reflectivecoating. The bulk material or the reflective coating may be a specularreflector, a diffuse reflector or a diffuse reflector that is backedwith a specular reflecting layer. Examples of reflective materials andreflective coatings were described previously. Preferably thereflectivity R_(E) of the inside surfaces of the light-recyclingenvelope 1102 that are not occupied by the semiconductor laser 1106 andthe light output aperture 1104 is at least 50%. More preferably, thereflectivity R_(E) is at least 70%. Most preferably, the reflectivityR_(E) is at least 90%. Ideally, the reflectivity R_(E) should be asclose to 100% as possible in order to maximize the efficiency and outputbrightness of the illumination system.

As illustrated in FIGS. 20A–20C, the wavelength conversion layer 1114substantially fills the interior of the light-recycling envelope 1102.Alternatively, the wavelength conversion layer 1114 may fill only asmall part of the light-recycling envelope, may entirely fill the partsof the light-recycling envelope that are not occupied by thesemiconductor laser 1106, may be a coating covering all or a part of theinside surfaces of only the light-recycling envelope, may be a coatingcovering all or a part of the inside surfaces of the light-recyclingenvelope and all or part of the exposed surfaces of the semiconductorlaser or may be a coating covering all or a part of the exposed surfacesof only the semiconductor laser.

The wavelength conversion layer 1114 converts light of a firstwavelength range emitted by the light source into light of a secondwavelength range, different from the light of a first wavelength range.The light of a second wavelength range has longer wavelengths and alower energy than the light of a first wavelength range, resulting in anenergy loss for wavelength conversion. The total energy efficiency η_(T)of wavelength conversion of light of a first wavelength range to lightof a second wavelength range is given previously by Equation 6.

As in previous examples, the wavelength conversion layer 1114 iscomprised of a powdered phosphor material, a quantum dot material, aluminescent dopant material or a plurality of such materials. Inaddition, the wavelength conversion layer 1114 may further comprise atransparent host material into which the powdered phosphor material, thequantum dot material or the luminescent dopant material is dispersed.Examples of powdered phosphor materials, quantum dot materials,luminescent dopant materials and transparent host materials are listedpreviously. For illustrative purposes, the wavelength conversion layer1114 in the FIGS. 20A–20C is shown to be comprised of particlesdispersed in a transparent layer.

Depending on the materials that comprise the wavelength conversion layer1114, the wavelength conversion layer may also partially reflect thelight of a first wavelength range and the light of a second wavelengthrange incident upon the wavelength conversion layer. Light may reflectinside the light-recycling envelope by reflecting from thelight-recycling envelope 1102, by partially reflecting from thewavelength conversion layer 1114 or by reflecting from the light source.However, in this case the surface area of the semiconductor laser lightsource is typically relatively small and reflects relatively littlelight. Light that passes through the wavelength conversion layer 1114and that is not reflected or absorbed by the wavelength conversion layerwill pass through to the opposite side of the wavelength conversionlayer. The wavelength conversion layer is chosen not to interfere withthe light-reflecting properties of the light-recycling envelope and thelight-recycling envelope is chosen not to interfere with the wavelengthconversion properties of the wavelength conversion layer.

Illumination system 1100 can have one or more than one light outputaperture. The total light output aperture area of all the light outputapertures in the illumination system is area A_(O). In FIGS. 20A–20C,illumination system 1100 is shown to have just one light output apertureand the area A_(O) for illumination system 1100 is the area of the onelight output aperture.

The light source for illumination system 1100 is at least onesemiconductor laser. It is also within the scope of this invention thatthe light source may be two or more semiconductor lasers. If a secondsemiconductor laser is present, the second semiconductor laser may emitlight of a first wavelength range or light of a third wavelength range,different than the first or second wavelength ranges. If a thirdsemiconductor laser is present, the third semiconductor laser may emitlight of a first, a third or a fourth wavelength range. Light of afourth wavelength range is different than light of a first, a second ora third wavelength range. For illustration purposes, the light sourcefor illumination system 1100 is shown as one semiconductor laser,denoted as semiconductor laser 1106, which is located on the left sideof the light-recycling envelope. Semiconductor laser 1106 may be anedge-emitting diode laser or a vertical cavity surface-emitting laser.Semiconductor lasers are generally fabricated from the same types ofmaterials as inorganic light-emitting diodes. Examples of inorganiclight-emitting diode materials have been listed previously.

The light source and the wavelength conversion layer operating incombination have a maximum combined intrinsic radiance of light of asecond wavelength range and a maximum combined intrinsic luminance oflight of a second wavelength range in the absence of a recyclingenvelope. The maximum combined intrinsic radiance of light of a secondwavelength range and the maximum combined intrinsic luminance of lightof a second wavelength range may be measured by either removing thelight-recycling envelope from illumination system 1100 and measuring theresulting brightness or by replacing the light-recycling envelope inillumination system 1100 with a light-transparent envelope and thenmeasuring the resulting brightness. The measurements are done in such away that any light of a first wavelength range is not included in themeasurements. This may require the use of a dichroic mirror or abandpass filter that allows only light of a second wavelength range toreach the measurement detector.

The total light-emitting area of the light source is area A_(S), butA_(S) is normally relatively small for a semiconductor laser and usuallydoes not represent a large fraction of the total inside area A_(T) ofthe light-recycling envelope. Just as for examples of the secondembodiment, the critical reference area for determining if brightnessenhancement can occur for examples of the third embodiment is themaximum cross-sectional area A_(E) of the light-recycling envelope andnot the area A_(S) of the light source.

Semiconductor laser 1106 emits light of a first wavelength range. Thelight of a first wavelength range emitted by the semiconductor laser1106 is preferably greater than 200 nanometers in wavelength and lessthan 3000 nanometers in wavelength. More preferably, the light of afirst wavelength range is greater than 200 nanometers in wavelength andless than 450 nanometers in wavelength.

The wavelength conversion layer 1114 of illumination system 1100 is incontact with semiconductor laser 1106. When the wavelength conversionlayer 1114 covers the semiconductor laser 1106, all light emitted bysemiconductor laser 1106 must pass through the wavelength conversionlayer 1114 at least once.

Representative light rays emitted by the semiconductor laser 1106 areillustrated in the cross-sectional view of illumination system 1100shown in FIG. 20C.

In FIG. 20C, a first light ray 1150 of a first wavelength range isemitted from semiconductor laser 1106, passes through the wavelengthconversion layer 1114 and passes through the remainder of the interiorof the light-recycling envelope 1102 to exit the light output aperture1104 without reflecting off the light-recycling envelope 1102 andwithout being converted by the wavelength conversion layer 1114.

A second light ray 1152 of a first wavelength range is emitted fromsemiconductor laser 1106 in a first time period and enters thewavelength conversion layer 1114. The wavelength conversion layer 1114converts the light ray 1152 of a first wavelength range into light ray1154 of a second wavelength range, different from the light of a firstwavelength range. The light ray 1154 may be emitted in any direction bythe wavelength conversion layer. In this example, light ray 1154 passesthrough the remainder of the wavelength conversion layer and passesthrough the remainder of the interior of the light-recycling envelope1102 to reach the light-recycling envelope on the right side ofillumination system 1100. Light ray 1154 is reflected by thelight-recycling envelope and is recycled back to the wavelengthconversion layer 1114. Wavelength conversion layer 1114 is a partialreflector in addition to being a wavelength conversion layer. Light ray1154 is reflected by the wavelength conversion layer in a second timeperiod and exits the illumination system 1100 through the light outputaperture 1104. When the wavelength conversion layer reflects light ray1154 in the second time period, light ray 1154 adds to light of a secondwavelength range concurrently being emitted by the wavelength conversionlayer in the second time period. The reflected light rays increase theexiting radiance of light of a second wavelength range and the exitingluminance of light of a second wavelength range. Furthermore, theexiting radiance of light of a second wavelength range and the exitingluminance of light of a second wavelength range may, under someconditions, be higher than the respective maximum combined intrinsicradiance of light of a second wavelength range and the maximum combinedintrinsic luminance of light of a second wavelength range measured forillumination system 1100 in the absence of light recycling.

A third light ray 1156 of a first wavelength range is emitted fromsemiconductor laser 1106, passes part way through the wavelengthconversion layer 1114 and is converted to light ray 1158 of a secondwavelength range. Light ray 1158 passes through a part of the wavelengthconversion layer to the light-recycling envelope 1102 and is absorbed bythe light-recycling envelope.

A fourth light ray 1160 of a first wavelength range is emitted from thesemiconductor laser 1106, travels through the wavelength conversionlayer 1114 to the light-recycling envelope 1102, is reflected back intothe wavelength conversion layer by the light-recycling envelope andtravels part way across the wavelength conversion layer. The wavelengthconversion layer 1114 converts light ray 1160 of a first wavelengthrange into light ray 1162 of a second wavelength range, different fromthe light of a first wavelength range. Light ray 1162 passes through theremainder of the wavelength conversion layer 1114, passes through theremainder of the light-recycling envelope 1102 and exits illuminationsystem 1100 through the light output aperture 1104 as light of a secondwavelength range.

Light rays 1154 and 1160 illustrate rays that are reflected one time bythe light-recycling envelope. In general, light rays may reflect manytimes inside the light-reflecting envelope before either exiting theillumination system through light output aperture 1104 or being absorbedby the light-recycling envelope, the wavelength conversion layer, or thelight source. A multitude of light pathways is possible. Light of afirst wavelength range may be converted to light of a second wavelengthrange on the first pass through the wavelength conversion layer, may beconverted only after many passes through the wavelength conversionlayer, or may exit the illumination system without being converted.Light that has already been converted to light of a second wavelengthrange will not be converted again. The light-recycling envelope directsa part of the light of a first wavelength through the wavelengthconversion layer multiple times and increases the likelihood that thelight of a first wavelength range will be converted to light of a secondwavelength range.

In FIG. 20C, light ray 1150 is not converted to light of a secondwavelength range. Light rays 1152, 1156 and 1160 of a first wavelengthrange are converted into light of a second wavelength range. Overall,the wavelength conversion layer converts a portion of the light of afirst wavelength range into light of a second wavelength range,different than the first wavelength range.

Light ray 1150 of a first wavelength range and light ray 1162 of asecond wavelength range are not recycled back to the wavelengthconversion layer. Light ray 1160 of a first wavelength range and lightray 1154 of a second wavelength range are recycled back the wavelengthconversion layer by the light-recycling envelope 1102. Overall, onlypart of the light of a first wavelength range and part of the light of asecond wavelength range are recycled back to the wavelength conversionlayer by the light-recycling envelope.

Light ray 1158 passes through the wavelength conversion layer and isabsorbed by the light-recycling envelope 1102. In general, thelight-recycling envelope 1102 is not a perfect reflector and has areflectivity less than 100%. Some of the light of a first wavelengthrange and some of the light of a second wavelength range, such as lightray 1158, will be absorbed. Due to the absorption losses, only afraction of the light of a second wavelength range that is inside thelight-recycling envelope will exit the light-recycling envelope throughthe light output aperture 1104.

Another example of the third embodiment is illumination system 1200illustrated in cross-section in FIG. 21. Illumination system 1200 iscomprised of a light-recycling envelope 1102, a semiconductor laser1106, a wavelength conversion layer 1114 and a partially reflectingoptical element 1202. Illumination system 1200 is identical toillumination system 1100 except for the addition of the partiallyreflecting optical element 1202. Partially reflecting optical element1202 is preferably either a reflective polarizer or a dichroic mirror.

As stated previously, a reflective polarizer is a polarizer thatreflects light of a first polarization state and transmits light of asecond polarization state. Polarization states can be states of linearpolarization or states of circular polarization. Examples of suitablereflective polarizers were previously listed. The reflective polarizeris placed adjacent to the light output aperture 1104 and placed in theoptical path of light exiting from the light output aperture 1104. Theadjacent position of the reflective polarizer can be either just outsidethe light-recycling envelope or just inside the light-recyclingenvelope. The reflective polarizer reflects both light of a firstwavelength range and light of a second wavelength range that have afirst polarization state. Also, the reflective polarizer transmits bothlight of a first wavelength range and light of a second wavelength rangethat have a second polarization state. The light of a first polarizationstate, either light of a first wavelength range or light of a secondwavelength range, is recycled back into the light-recycling envelope.The light of a first polarization state recycled back into thelight-recycling envelope will, after multiple reflections, be convertedinto a mixture of light of a first polarization state and light of asecond polarization state. The converted light of a second polarizationstate will then be able to pass through the reflecting polarizer. Ifonly light of a second polarization state is desired for the output ofillumination system 1200, recycling the light of a first polarizationstate back into the light-reflecting envelope 1102 to be converted intolight of a second polarization state will improve the overall efficiencyand output brightness of illumination system 1200.

As stated previously, some applications require polarized light. Forexample, flat-panel display or projection display applications thatincorporate liquid crystal display (LCD) panels orliquid-crystal-on-silicon (LCOS) display panels require polarized light.

A dichroic mirror is, for example, a mirror that can reflect light of afirst wavelength range and transmit light of a second wavelength range.Dichroic mirrors may be utilized if light of a first wavelength rangeemitted by semiconductor laser 1106 is not desired in the light outputfrom the light-recycling envelope. Dichroic mirrors are commonlyconstructed by alternately depositing layers of two transparentdielectrics having different indexes of refraction onto a transparentsubstrate. Examples of materials used for dielectric coating layersinclude silicon dioxide, titanium dioxide or magnesium fluoride.

When the partially transparent optical element 1202 is a dichroicmirror, the dichroic mirror is placed adjacent to the light outputaperture 1104 and placed in the optical path of light exiting from thelight output aperture 1104. The adjacent position of the dichroic mirrorcan be either just outside the light-recycling envelope or just insidethe light-recycling envelope. In FIG. 21, the partially reflectingoptical element 1202 is a dichroic mirror and is positioned just outsidethe light output aperture 1104.

The function of the dichroic mirror in FIG. 21 is illustrated usinglight rays 1210, 1212 and 1214. Light ray 1210 of a first wavelengthrange is emitted from the semiconductor laser 1106, passes through thewavelength conversion layer 1114 a first time without being convertedand travels to the light-recycling envelope 1102. The light-recyclingenvelope 1102 reflects and recycles light ray 1210 back through thewavelength conversion layer 1114. Light ray 1210 passes through thewavelength conversion layer a second time without being converted,passes through the remainder of the interior of the light-recyclingenvelope 1102 and passes through the light output aperture 1104 a firsttime to reach the partially reflecting optical element 1202, which inthis example is a dichroic mirror. Light ray 1210 reflects off thedichroic mirror, passes through the light output aperture 1104 a secondtime and is recycled back into the interior of the light-recyclingenvelope 1102.

Light ray 1212 of a first wavelength range is emitted by thesemiconductor laser 1106 and passes through a part of the wavelengthconversion layer 1114. The wavelength conversion layer 1114 convertslight ray 1212 of a first wavelength range into light ray 1214 of asecond wavelength range. Light ray 1214 may be emitted in any direction.In this example, light ray 1214 passes through the remainder of thewavelength conversion layer, passes through the remainder of theinterior of the light-recycling envelope 1102, passes through the lightoutput aperture 1104 and passes through the partially reflecting opticalelement 1202, which is the dichroic mirror.

Overall, the dichroic mirror transmits light of a second wavelengthrange and reflects and recycles light of a first wavelength range backinto the light-recycling envelope. The wavelength conversion layer canthen convert the light of a first wavelength range that is recycled backinto the light-recycling envelope into light of a second wavelengthrange. The converted light of a second wavelength range can then passthrough the dichroic mirror. If only light of a second wavelength rangeis desired for the output of illumination system 1200, recycling thelight of a first wavelength range back into the light-reflectingenvelope to be converted into light of a second wavelength range willimprove the overall efficiency and output brightness of illuminationsystem 1200.

In FIGS. 20 and 21, the light source is positioned inside thelight-recycling envelope. The light-recycling envelope encloses thelight source and the wavelength conversion layer. It is also within thescope of the third embodiment of this invention that a part of the lightsource may be located outside the light-recycling envelope. In suchcases, the light-recycling envelope partially encloses the light sourcebut does not enclose the entire light source. An example of anillumination system where a part of the light source is located outsidethe light-recycling envelope is shown in the cross-sectional view inFIG. 22.

FIG. 22 shows a cross-sectional view of illumination system 1300.Illumination system 1300 is similar to illumination system 1100 exceptthat the light source for illumination system 1300 comprises light guide1320 in addition to a semiconductor laser 1306. Illumination system 1300also comprises a light-recycling envelope 1302, a wavelength conversionlayer 1314 and a light output aperture 1304. The characteristics andproperties of elements 1306, 1302, 1314 and 1304 are identical to thecharacteristics and properties of the respective elements inillumination system 100. It is also within the scope of this inventionthat illumination system 1300 may include a plurality of semiconductorlasers associated with a plurality of light guides.

The light-recycling envelope 1302 has a maximum cross-sectional areaA_(E). The light source, comprising semiconductor laser 1306 and lightguide 1320, and the wavelength conversion layer 1314 operating incombination have a maximum combined intrinsic radiance of light of asecond wavelength range and a maximum combined intrinsic luminance oflight of second wavelength range in the absence of light recycling.Light of a first wavelength range is not included in the brightnessmeasurements.

Light guide 1320 is located between the semiconductor laser 1306 and thelight-recycling envelope 1302. Light guide 1320 has an input surface1321 adjacent to the semiconductor laser 1306 and an output surface 1322located inside the light-recycling envelope 1302. Light guide 1320transports light of a first wavelength range emitted by thesemiconductor laser 1306 from the semiconductor laser 1306 into thelight-recycling envelope 1302.

The light guide 1320 is any structure that transports light of a firstwavelength range. For example, light guide 1320 may be constructed fromany solid material that transports light by total internal reflection.Possible materials include inorganic glasses such as silicon dioxide andplastics such as polymethymethacrylate and fluoroacrylates. The lightguide 1320 may also be a solid or hollow structure where the sides, butnot the ends, of the structure are coated with a light reflectingmaterial. Furthermore, light guide 1320 may be a single-mode ormulti-mode optical fiber that contains a core material and a claddingmaterial having a lower index of refraction than the core material. Theoptical fiber may be constructed from inorganic glasses or transparentpolymers. Such materials are well known to persons skilled in the art ofoptical fibers.

As noted previously, the light-recycling envelope 1302 has reflectivityR_(E) and R_(E) is preferably at least 50%. More preferably, thereflectivity R_(E) is at least 70%. Most preferably, the reflectivityR_(E) is at least 90%. The total output aperture area of output aperture1304 is area A_(O). As in illumination system 1100, when A_(O) is lessthan A_(E) and when R_(E) is greater than 50%, it is possible for theexiting radiance of light of a second wavelength range exiting fromillumination system 1300 to be greater than the maximum combinedintrinsic radiance of light of a second wavelength range emitted by thelight source, comprising semiconductor laser 1306 and light guide 1320,and the wavelength conversion layer 1314 operating in combination. It isalso possible for the exiting luminance of light of a second wavelengthrange exiting from illumination system 1300 to be greater than themaximum combined intrinsic luminance of light of a second wavelengthrange emitted by the light source, comprising semiconductor laser 1306and light guide 1320, and the wavelength conversion layer 1314 operatingin combination.

Example rays 1330, 1332, 1334 and 1336 illustrate the functioning oflight-recycling envelope to recycle light. Light ray paths inside thelight guide 1320 originating at the semiconductor laser 1306 are notshown. Light ray 1330 of a first wavelength range coming fromsemiconductor laser 1306 is emitted from surface 1322 of light guide1320 in a first time period, passes through the wavelength conversionlayer 1314 and a part of the interior of the light-recycling envelope1302 and is reflected and recycled back into the wavelength conversionlayer by the light-recycling envelope 1302 in a second time period.Light ray 1330 passes part way through the wavelength conversion layerand is converted into light ray 1332 of a second wavelength range. Lightray 1332 passes through a part of the wavelength conversion layer,passes through part of the interior of the light-recycling envelope andexits illumination system 1300 through light output aperture 1304 aslight of a second wavelength range.

Light ray 1334 of a first wavelength range coming from semiconductorlaser 1306 is emitted from output surface 1322 of light guide 1320 in afirst time period, passes through a part of the wavelength conversionlayer 1314 and is converted to light ray 1336 of a second wavelengthrange by the wavelength conversion layer. Light ray 1336 passes througha part of the wavelength conversion layer 1314 to the light-recyclingenvelope 1302 and is reflected and recycled by the light-recyclingenvelope back into the wavelength conversion layer 1314 in a second timeperiod. Light ray 1336 passes through the wavelength conversion layer,passes through the remainder of the interior of the light-recyclingenvelope and exits illumination system 1300 through the light outputaperture 1304 as light of a second wavelength range.

When light rays 1330 of a first wavelength range and 1336 of a secondwavelength range are recycled back into the wavelength conversion layer1314 in a second time period, light ray 1330 adds to the light of afirst wavelength range concurrently being emitted by the semiconductorlaser 1306 through the light guide 1320 in the second time period, andlight ray 1336 adds to the light of a second wavelength rangeconcurrently being emitted by the wavelength conversion layer 1314 inthe second time period. By utilizing light recycling, it is thenpossible for the exiting radiance of light of a second wavelength rangeexiting the light output aperture 1304 to be greater than the maximumcombined intrinsic radiance of light of a second wavelength rangeemitted by the light source and the wavelength conversion layeroperating in combination in the absence of recycling. In addition, it ispossible for the exiting luminance of light of a second wavelength rangeexiting the light output aperture 1304 to be greater than the maximumcombined intrinsic luminance of light of a second wavelength rangeemitted by the light source and the wavelength conversion layeroperating in combination in the absence of recycling.

In illumination system 1300, the semiconductor laser is removed from theinside of the light-recycling envelope. Semiconductor lasers generateconsiderable heat during operation. Removing the semiconductor laserfrom the light-recycling envelope lowers the temperature generatedinside the light-recycling envelope. This is advantageous, especiallywhen multiple semiconductor lasers are required for the illuminationsystem. Placing multiple semiconductor lasers away from thelight-recycling envelope will allow the semiconductor lasers to beoperated in a potentially cooler environment, which will increase thelight output and the operating lifetime of the semiconductor lasers.

The following EXAMPLES will further explain the embodiments of thisinvention.

EXAMPLE 1

A computer simulation program is used to model the relative outputradiance, the relative output luminance and the overall outputefficiency of an illumination system that has twelve identical LEDsources inside a light-recycling envelope. In this example, there is nowavelength conversion layer in the light-recycling envelope. Each LEDsource has dimensions of 2 mm×2 mm, a total light-emitting area of 4 mm²and emits 0.2 watts or 11 lumens of light at 450 nm. The value of 11lumens is calculated from the value in watts assuming a conversionfactor of 55 lumens per watt at 450 nm. Each LED has a maximum intrinsicradiance, Radiance_(I), and a maximum intrinsic luminance, L_(I). Themaximum intrinsic radiance or luminance of an LED is determined bymeasuring an identically constructed LED that is not enclosed in alight-recycling envelope. Each LED source is assumed to have aLambertian output light distribution. The total light-emitting areaA_(S) of the twelve LED sources is 48 mm² and the total emitted 450-nmlight flux from the twelve LED sources is 2.4 watts or 132 lumens. Thelight-recycling envelope has a square cross-section with insidedimensions of 2.8 mm×2.8 mm, inside length of 9 mm and a total insidearea of 116.48 mm². The total inside area includes the totallight-emitting area of the twelve LED sources and the area of the outputaperture. The light output aperture of the light-recycling envelope hasan area A_(O) of 4.8 mm² so that A_(O)/A_(S) equals 0.10, i.e. the areaof the light output aperture is 10% of the total light-emitting area ofthe LED sources. If the light-recycling envelope has no losses (i.e. ifthe light reflectivity of the LED sources and the inside reflectingsurfaces of the light-recycling envelope are 100%), the output radiance(or luminance) will be 10 times the radiance (or luminance) of the LEDsources and the output efficiency will be 100%. However, the actuallight-recycling envelope will have a light reflectivity less than 100%and will have losses. For simplicity, the specular reflectivity R_(S) ofthe LED sources is assumed to be identical in magnitude to the diffusereflectivity R_(E) of the inside light-reflecting surfaces of thelight-recycling envelope that are not covered by the LED sources. In thecalculations, the reflectivity R_(S) and the reflectivity R_(E) arevaried, having values of 40%, 50%, 60%, 70%, 80%, 90%, or 98%. Theresults are shown below in TABLE 1. The ratio,Radiance_(O)/Radiance_(I), of the output radiance, Radiance_(O), to theintrinsic radiance, Radiance_(I), of the LED sources indicates theradiance (brightness) enhancement resulting from light recycling. Theratio, L_(O)/L_(I), of the output luminance L_(O) to the intrinsicluminance L_(I) is the luminance enhancement resulting from lightrecycling and is also calculated. Since there is no wavelengthconversion inside the light-recycling envelope, the radiance enhancementand the luminance enhancement are equal. The calculated efficiency isthe percentage of light flux generated by the sources that passesthrough the output aperture. The remainder of the light flux is lost dueto absorption by the sources and the light-recycling envelope. Thecomputer modeling results indicate that when R_(S) and R_(E) equal 50%or less, there is no radiance enhancement (Radiance_(O)/Radiance_(I) isless than 1) or luminance enhancement (L_(O)/L_(I) is less than 1) andthe efficiency is low (less than 10%). As the reflectivity of the LEDsources and the light-recycling envelope increases, the radianceenhancement, the luminance enhancement and the efficiency increase. WhenR_(S) equals 98% and R_(E) equals 98%, the radiance or luminanceenhancement factor of 6.87 indicates that the output radiance or outputluminance from the light output aperture of the illumination system is6.87 times larger than the intrinsic radiance or luminance of the LEDsources.

TABLE 1 Light- Total Total recycling light Radiance light Area Sourceenvelope flux enhancement flux Luminance ratio R_(S) R_(E) Efficiencyout (Radiance_(O)/ out enhancement A_(O)/A_(S) (%) (%) (%) (watts)Radiance_(I)) (lumens) (L_(O)/L_(I)) 0.10 40 40 7.9 0.19 0.79 10.4 0.790.10 50 50 9.2 0.22 0.91 12.1 0.91 0.10 60 60 10.8 0.26 1.08 14.3 1.080.10 70 70 13.8 0.33 1.38 18.2 1.38 0.10 80 80 19.2 0.46 1.89 25.3 1.890.10 90 90 31.1 0.75 3.11 41.1 3.11 0.10 98 98 68.7 1.65 6.87 91.7 6.87

EXAMPLE 2

The illumination system in EXAMPLE 2 is similar to EXAMPLE 1 except thatthe diffuse reflectivity R_(E) of the inside surfaces of thelight-recycling envelope is held constant at 98% and the specularreflectivity R_(S) of the LED sources is varied from 5% to 98%. There isno wavelength conversion layer in the light-recycling envelope. In thisexample, a computer simulation program is used to calculate the relativeoutput radiance, output luminance and the overall output efficiency of alight-recycling envelope containing twelve identical LED sources. EachLED has a maximum intrinsic radiance, Radiance_(I), and a maximumintrinsic luminance, L_(I). The maximum intrinsic radiance or luminanceof an LED is determined by measuring an identically constructed LED thatis not enclosed in a light-recycling envelope. The light output apertureof the light-recycling envelope has an area A_(O) of 4.8 mm² so thatA_(O)/A_(S) equals 0.10, i.e. the area of the light output aperture is10% of the total area of the LED sources. The ratio,Radiance_(O)/Radiance_(I), of the output radiance, Radiance_(O), to theintrinsic radiance, Radiance_(I), of the LED sources indicates theradiance (brightness) enhancement resulting from light recycling. Theratio, L_(O)/L_(I), of the output luminance L_(O) to the intrinsicluminance L_(I) is the luminance enhancement resulting from lightrecycling and is also calculated. The results are shown in TABLE 2.Since there is no wavelength conversion inside the light-recyclingenvelope, the radiance enhancement and the luminance enhancement areequal. The calculated efficiency is the percentage of light fluxgenerated by the sources that passes through the output aperture. Theremainder of the light flux is lost due to absorption by the sources andthe light-recycling envelope. The computer modeling results indicatethat for R_(S) equal to 10% or less and R_(E) equal to 98%, there is noradiance enhancement (Radiance_(O)/Radiance_(I) is less than 1) orluminance enhancement (L_(O)/L_(I) is less than 1) and the efficiency isrelatively low (less than 10%). Note that typical blackbody or gray bodylight sources have low reflectivity (less than 10%), and the results inthis EXAMPLE indicate that such sources are not suitable for use in thisinvention. As the reflectivity of the sources increases, the radianceenhancement, the luminance enhancement and the efficiency increase. WhenR_(S) equals 98% and R_(E) equals 98%, the radiance or luminanceenhancement factor of 6.87 indicates that the output radiance or outputluminance from the light output aperture of the illumination system is6.87 times larger than the intrinsic radiance or luminance of the LEDsources.

TABLE 2 Light- Total Total recycling light Radiance light Area Sourceenvelope flux enhancement flux Luminance ratio R_(S) R_(E) Efficiencyout (Radiance_(O)/ out enhancement A_(O)/A_(S) (%) (%) (%) (watts)Radiance_(I)) (lumens) (L_(O)/L_(I)) 0.10 5 98 9.3 0.22 0.93 12.3 0.930.10 10 98 9.7 0.23 0.97 12.8 0.97 0.10 20 98 10.8 0.26 1.08 14.3 1.080.10 30 98 12.4 0.30 1.24 16.4 1.24 0.10 40 98 13.9 0.33 1.39 18.3 1.390.10 50 98 16.2 0.39 1.62 21.4 1.62 0.10 60 98 19.2 0.46 1.92 25.3 1.920.10 70 98 23.7 0.57 2.37 31.3 2.37 0.10 80 98 31.1 0.75 3.11 41.1 3.110.10 90 98 44.2 1.06 4.42 58.3 4.42 0.10 98 98 68.7 1.65 6.87 90.7 6.87

EXAMPLE 3

The illumination system in EXAMPLE 3 is similar in configuration toEXAMPLE 1 and EXAMPLE 2 except that a wavelength conversion layer ispresent inside the light-recycling envelope. The wavelength conversionlayer is a powdered phosphor dispersed in a host material. The powderedphosphor is cerium doped yttrium aluminum garnet (YAG:Ce³⁺ orY₃Al₅O₁₂:Ce³⁺), which converts 450-nm blue light to 580-nm yellow light.The wavelength conversion layer is coated over the portion of the insidesurfaces of the light-recycling envelope that are not covered by the LEDsources. A computer simulation program is used to model the outputradiance, the radiance enhancement, the output luminance, the luminanceenhancement and the overall output efficiency of an illumination systemthat has a light-recycling envelope containing twelve identical LEDsources. Each LED source has dimensions of 2 mm×2 mm, a totallight-emitting area of 4 mm² and emits 0.2 watts or 11 lumens of lightat 450 nm. The value of 11 lumens is calculated from the value in wattsassuming a conversion factor of 55 lumens per watt at 450 nm. Each LEDhas a maximum intrinsic radiance, Radiance_(I), and a maximum intrinsicluminance, L_(I). The maximum intrinsic radiance or luminance of an LEDis determined by measuring an identically constructed LED that is notenclosed in a light-recycling envelope. Each LED source is assumed tohave a Lambertian output light distribution. The total light-emittingarea A_(S) of the twelve LED sources is 48 mm² and the total emitted450-nm light flux from the twelve LED sources is 2.4 watts or 132lumens. The light-recycling envelope has a square cross-section withinside dimensions of 2.8 mm×2.8 mm, inside length of 9 mm and a totalinside area of 116.48 mm². The total inside area includes the totallight-emitting area of the twelve LED sources, the area covered by thewavelength conversion layer and the area of the output aperture. Thearea covered by the wavelength conversion layer is 63.68 mm². The lightoutput aperture of the light-recycling envelope has an area A_(O) of 4.8mm² so that A_(O)/A_(S) equals 0.10, i.e. the area of the light outputaperture is 10% of the total light-emitting area of the LED sources. Ifthe light-recycling envelope has no losses (i.e. if the lightreflectivity of the LED and the inside reflecting surfaces are 100%),the output radiance from the light output aperture will be 10 times theradiance of the LED sources (due to the area ratio A_(S)/A_(O) equaling10) and the output efficiency will be 100%. However, the actuallight-recycling envelope has light reflectivity less than 100% and haslosses. In this example, the specular reflectivity R_(S) of the LEDsources is 90% and the total diffuse reflectivity R_(E) of the insidelight-reflecting surfaces of the light-recycling envelope that are notcovered by the LED sources is 98%. The total diffuse reflectivity R_(E)is the total reflectivity of the inside surfaces of the light-recyclingenvelope, including the reflectivity of the wavelength conversion layer.The effects of the wavelength conversion layer will depend on thethickness of the material and the degree of phosphor loading. If thewavelength conversion layer is relatively thick or the phosphor loadingis high, each time blue light strikes the wavelength conversion layer,the fraction F of the blue light that is converted to yellow light islarge. Conversely, if the wavelength conversion layer is relatively thinor the phosphor loading is low, each time the blue light strikes thewavelength conversion layer, the fraction F of the blue light that isconverted to yellow light is small. In this calculation, the conversionfraction F is varied from 0.0 (no blue light converted) to 1.0 (all bluelight converted). Each time a blue light photon is absorbed by thephosphor, energy losses will take place. The first energy loss occurs ifthe quantum efficiency of converting blue light to yellow light is notequal to unity. It is assumed for this calculation that the quantumefficiency is 95%. The second energy loss, the Stokes shift energy loss,occurs because the energy of a 580-nm yellow photon generated by thewavelength conversion layer is less than the energy of the original450-nm blue photon. The remainder of the blue photon energy is lost toheat. In this example, the 580-nm yellow photon has 78% of the energy ofa 450-nm blue photon. The results for the radiance simulations are shownbelow in TABLE 3. The ratio, Radiance_(O)/Radiance_(I), of the outputradiance, Radiance_(O), from the light output aperture to the intrinsicradiance, Radiance_(I), of the LED sources indicates the radiance(brightness) enhancement resulting from light recycling. The calculatedefficiency is the percentage of light flux generated by the sources thatpasses through the light output aperture. The remainder of the lightflux is lost due to absorption by the sources and the light-recyclingenvelope. The maximum radiance enhancement value of 4.42 occurs when nowavelength conversion takes place (F equals 0). The total efficiency andthe radiance enhancement are reduced as F increases from 0 to 1, but theradiance enhancement still remains greater than 3.00. In TABLE 4, thelight output flux values in watts are converted to lumens to illustratethe brightness enhancement as observed by the human eye. The conversionfactors used for TABLE 4 are 55 lumens per watt for 450-nm light and 590lumens per watt for 580-nm light.

TABLE 3 Radiance Blue Yellow Total light Total enhancement light outlight out flux out efficiency (Radiance_(O)/ F (watts) (watts) (watts)(%) Radiance_(I)) 0.0 1.06 0.00 1.06 44.2 4.42 0.2 0.49 0.42 0.91 38.23.82 0.4 0.32 0.55 0.87 36.3 3.63 0.6 0.24 0.61 0.85 35.5 3.55 0.8 0.190.65 0.84 35.0 3.50 1.0 0.16 0.67 0.83 34.6 3.46

TABLE 4 Total Total Blue Yellow light Blue Yellow light light light fluxTotal light light flux Luminance out out out (eff.) out out outenhancement F (watts) (watts) (watts) (%) (lumens) (lumens) (lumens)(L_(O)/L_(I)) 0.0 1.06 0.00 1.06 44.2 58.3 0 58.3 4.4 0.2 0.49 0.42 0.9138.2 27.0 247.8 274.8 20.8 0.4 0.32 0.55 0.87 36.3 17.6 324.5 342.1 25.90.6 0.24 0.61 0.85 35.5 13.2 359.9 373.1 28.3 0.8 0.19 0.65 0.84 35.010.5 383.5 394.0 29.9 1.0 0.16 0.67 0.83 34.6 8.8 395.3 404.1 30.6

The ratio, L_(O)/L_(I), of the output luminance L_(O) from the lightoutput aperture to the intrinsic luminance L_(I) is the luminanceenhancement. The luminance enhancement is a result both of lightrecycling and wavelength conversion. If there is no wavelengthconversion (F equals 0), the luminance enhancement of 4.4 is equal tothe radiance enhancement. As F increases from 0 to 1, the luminanceenhancement increases as a result of wavelength conversion. Although theefficiency is lowest (34.6%) at F equal to 1, the luminance enhancementis a maximum at F equal to 1 since more blue light is converted toyellow light and the human eye is more sensitive to yellow light. At Fequal to 1, the luminance at the light output aperture is over 30 timeshigher than the intrinsic luminance L_(I) of the LED sources.

While the invention has been described in conjunction with specificembodiments and examples, it is evident to those skilled in the art thatmany alternatives, modifications and variations will be apparent inlight of the foregoing description. Accordingly, the invention isintended to embrace all such alternatives, modifications and variationsas fall within the spirit and scope of the appended claims.

1. An illumination system, comprising: a light source, wherein saidlight source further comprises an emitting layer and a reflecting layer,wherein said emitting layer emits light of a first wavelength range andwherein the total light-emitting area of said light source is areaA_(S); a wavelength conversion layer, wherein said wavelength conversionlayer converts a portion of said light of a first wavelength range intolight of a second wavelength range, different from said light of a firstwavelength range; a light-recycling envelope, wherein saidlight-recycling envelope is separate from said wavelength conversionlayer, wherein said light-recycling envelope at least partially enclosessaid light source and said wavelength conversion layer, wherein themaximum cross-sectional area of said light-recycling envelope is areaA_(E), wherein said light-recycling envelope has reflectivity R_(E) andwherein said light-recycling envelope reflects and recycles part of saidlight of a first wavelength range and part of said light of a secondwavelength range back to said reflecting layer or to said wavelengthconversion layer as recycled light; and at least one light outputaperture, wherein said at least one light output aperture is located ina surface of said light-recycling envelope, wherein the total lightoutput aperture area is area A_(O), wherein said light source and saidwavelength conversion layer and said light-recycling envelope direct atleast a fraction of said light of a first wavelength range and at leasta fraction of said light of a second wavelength range out of saidlight-recycling envelope through said at least one light output apertureas incoherent light and wherein said recycled light reflected from saidlight-recycling envelope produces increased light output brightnessthrough said at least one light output aperture.
 2. An illuminationsystem as in claim 1, wherein said light of a first wavelength rangeemitted by said light source has a maximum intrinsic source radiance anda maximum intrinsic source luminance, wherein said fraction of saidlight of a first wavelength range and said fraction of said light of asecond wavelength range exiting said at least one light output aperturehave a combined exiting radiance and a combined exiting luminance andwherein said area A_(O) is less than said area A_(S).
 3. An illuminationsystem as in claim 2, wherein said combined exiting radiance is greaterthan said maximum intrinsic source radiance.
 4. An illumination systemas in claim 2, wherein said combined exiting luminance is greater thansaid maximum intrinsic source luminance.
 5. An illumination system as inclaim 1, wherein said light source and said wavelength conversion layeroperating in combination have a maximum combined intrinsic radiance anda maximum combined intrinsic luminance, wherein said fraction of saidlight of a first wavelength range and said fraction of said light of asecond wavelength range exiting said at least one light output aperturehave a combined exiting radiance and a combined exiting luminance andwherein said area A_(O) is less than said area A_(E).
 6. An illuminationsystem as in claim 5, wherein said combined exiting radiance is greaterthan said maximum combined intrinsic radiance.
 7. An illumination systemas in claim 5, wherein said combined exiting luminance is greater thansaid maximum combined intrinsic luminance.
 8. An illumination system asin claim 1, wherein said light source and said wavelength conversionlayer operating in combination have a maximum combined intrinsicradiance of light of a second wavelength range and a maximum combinedintrinsic luminance of light of a second wavelength range, wherein saidfraction of said light of a second wavelength range exiting said atleast one light output aperture has an exiting radiance of light of asecond wavelength range and an exiting luminance of light of a secondwavelength range and wherein said area A_(O) is less than said areaA_(E).
 9. An illumination system as in claim 8, wherein said exitingradiance of light of a second wavelength range is greater than saidmaximum combined intrinsic radiance of light of a second wavelengthrange.
 10. An illumination system as in claim 8, wherein said exitingluminance of light of a second wavelength range is greater than saidmaximum combined intrinsic luminance of light of a second wavelengthrange.
 11. An illumination system as in claim 1, wherein said reflectinglayer of said light source at is located on an inside surface of saidlight-recycling envelope.
 12. An illumination system as in claim 1,wherein said light of a first wavelength range is greater than 200nanometers in wavelength and less than 3000 nanometers in wavelength.13. An illumination system as in claim 12, wherein said light of a firstwavelength range is greater than 200 nanometers in wavelength and lessthan 450 nanometers in wavelength.
 14. An illumination system as inclaim 1, wherein said light source further emits light of a thirdwavelength range, different than said light of a first wavelength rangeand said light of a second wavelength range.
 15. An illumination systemas in claim 14, wherein said light source emits said light of a thirdwavelength range concurrently with the emission of said light of a firstwavelength range and said light of a second wavelength range and whereinsaid fraction of said light of a first wavelength range and saidfraction of said light of a second wavelength range and a fraction ofsaid light of a third wavelength range exit said at least onelight-output aperture as light of a composite color.
 16. An illuminationsystem as in claim 14, wherein the amount of said light of a thirdwavelength range emitted by said light source is changed in order tovary the color and the color-rendering index of said light of acomposite color.
 17. An illumination system as in claim 14, wherein saidlight source emits said light of a third wavelength range in a firsttime period, wherein said light of a first wavelength range and saidlight of a second wavelength range are emitted in a second time period,different than the first time period, wherein a fraction of said lightof a third wavelength range exits said at least one light outputaperture in said first time period, wherein said fraction of said lightof a first wavelength range and said fraction of said light of a secondwavelength range exit said at least one light-output aperture in saidsecond time period and wherein said first time period and said secondtime period are repeated in sequence.
 18. An illumination system as inclaim 1, wherein said light source further comprises at least one lightguide, wherein said light guide has an input surface adjacent to saidemitting layer of said light source, wherein said light guide has anoutput surface located inside said light-recycling envelope, whereinsaid light guide transports said light of a first wavelength range fromsaid light source to said light-recycling envelope.
 19. An illuminationsystem as in claim 1, wherein said wavelength conversion layer fills asubstantial portion of said light-recycling envelope and wherein saidwavelength conversion layer covers said emitting layer of said lightsource.
 20. An illumination system as in claim 1, wherein saidwavelength conversion layer coats at least a portion of the insidesurfaces of said light-recycling envelope.
 21. An illumination system asin claim 1, wherein said wavelength conversion layer coats at least aportion of said emitting layer of said light source that emits saidlight of a first wavelength range.
 22. An illumination system as inclaim 1, wherein said light-recycling envelope is constructed from abulk material that is intrinsically reflective.
 23. An illuminationsystem as in claim 1, wherein the inside surfaces of saidlight-recycling envelope are covered with a reflective coating.
 24. Anillumination system as in claim 23, wherein said reflective coating is adiffuse reflector.
 25. An illumination system as in claim 23, whereinsaid reflective coating is a specular reflector.
 26. An illuminationsystem as in claim 23, wherein said reflective coating is a diffusereflector that is backed by a specular reflector.
 27. An illuminationsystem as in claim 1, further comprising a reflective polarizer, whereinsaid reflective polarizer is located in the light output optical path,wherein said reflective polarizer is located adjacent to said at leastone light output aperture of said light-recycling envelope, wherein saidreflective polarizer reflects said light of a first polarization stateback into said light-recycling envelope and wherein said reflectivepolarizer transmits said light of a second polarization state.
 28. Anillumination system as in claim 1, further comprising a dichroic mirror,wherein said dichroic mirror is located in the light output opticalpath, wherein said dichroic mirror is located adjacent to said at leastone light output aperture of said light-recycling envelope, wherein saiddichroic mirror reflects said light of a first wavelength range backinto said light-recycling envelope and wherein said dichroic mirrortransmits said light of a second wavelength range.
 29. An illuminationsystem as in claim 1, further comprising a light collimating element,wherein said light collimating element partially collimates the lightexiting said at least one light output aperture.